A split formwork trolley system and construction method

Abstract

The application discloses a separated formwork trolley system, which comprises a walking system, a support system and a formwork system, the bottom end of the support system is detachably connected with the top end of the walking system, and the formwork system is detachably connected with the top end and the side wall of the support system; the application provides a device and a method which can be used in the construction of large-section tunnel lining under the double-side-wall drift method or the CRD method, can meet the requirements of reducing construction period, facilitating construction and mechanized operation, and solves the problem of low automation degree of the traditional formwork construction method in underground engineering. The method improves the traditional integral formwork trolley and redevelops the formwork trolley, and finally, a separated formwork trolley is provided, which has high mechanization degree, good safety performance, high construction efficiency and can meet the construction of large-section tunnel lining under the "jumping warehouse method", promotes the development of mechanized construction in underground engineering, provides a new thought and experience for the automatic construction of tunnel engineering, has strong innovation, and will produce high economic benefits and social benefits.

Description

Technical Field

[0001] This invention belongs to the field of tunnel construction technology, and in particular relates to a separate formwork trolley system and construction method. Background Technology

[0002] In recent years, with the rapid development of underground engineering construction, the number of tunnel projects has gradually increased, involving a large amount of formwork engineering. The common system is mainly steel pipe scaffolding (cuplock scaffolding) + wooden (steel) formwork. However, the above-mentioned formwork system has a low degree of automation, high manpower input, long installation and dismantling cycle, complicated erection process, and is prone to accidents if not erected properly. This has led to a widening gap between this formwork system and the needs of modern intelligent construction, and it can no longer meet the requirements of modern engineering. Moreover, with the aging population and changes in the talent structure in China, this purely manual construction technology urgently needs to be transformed.

[0003] Therefore, in the 1950s, the integrated formwork trolley, a semi-automated formwork assembly device, emerged and was subsequently used in highway, railway, subway, and hydraulic tunnels in countries such as the United States, the United Kingdom, and Japan. my country introduced this technology in 1978 in the Dayaoshan Tunnel on the Beijing-Guangzhou Railway. Compared with traditional methods, the integrated formwork trolley has a higher degree of automation, is more convenient to construct, produces higher quality work, and is easier to maintain, leading to its widespread application in tunnel engineering in my country. However, large-section excavation in soft strata is unavoidable in tunnel construction, and urban subway tunnel construction has extremely stringent requirements for surface deformation, limiting full-section excavation technology and necessitating the use of methods such as CRD (Continuous Reduction) or double-sided pilot tunnels. Therefore, the integrated formwork trolley, adapted to full-section excavation technology, also needs adjustment and modification to suit these methods.

[0004] In the secondary lining construction of large-section tunnels excavated using the CRD method or double-sided pilot tunnel method, temporary supports and permanent linings interfere with each other spatially, requiring the temporary supports to be removed before lining formwork. Currently, three commonly used methods for removing temporary supports are anchoring, arching, and skipping sections. Anchoring relies heavily on the anchoring and bearing capacity of deep strata, while arching is mostly used in double-layer initial support composite arch tunnels in soft-overhead, hard-underhead strata, limiting the application of these two methods. The skipping section method, however, retains a temporary partition wall between the two sections, reducing dependence on the strata and surrounding environment, increasing adaptability, and offering greater operational flexibility, making it widely used in large-section tunnel projects. Therefore, the skipping section method is frequently used for secondary lining construction in large-section tunnels excavated using the CRD method or double-sided pilot tunnel method.

[0005] Before secondary lining construction, formwork is required. The most common method is to manually erect a full-span scaffold plus steel formwork. Two other methods exist: First, an integrated formwork trolley, consisting of a traveling system, formwork system, and scaffolding system, travels along pre-laid tracks, allowing for one-time casting of the tunnel sidewalls and arch. This method offers high automation, efficiency, and low risk, but its drawbacks include the need for sequential lining casting, repeated installation and dismantling which wastes time and affects the trolley's lifespan. Furthermore, it cannot be used for the "skip-panel" method in large-section tunnel lining construction. Second, a modular formwork scaffold, which can also form the sidewalls and arch in one go, and allows for significant adjustment of the formwork outline and curvature, making it highly suitable for variable-section tunnels. Modular formwork installation is more convenient and flexible than traditional full-span scaffolding; however, it still requires manual erection, transportation, and dismantling, limiting its efficiency in improving the construction of large-section tunnel linings. Moreover, manual operation has low automation and significant safety hazards. Therefore, a separate formwork trolley system and construction method are needed to address these issues. Summary of the Invention

[0006] The purpose of this invention is to provide a separate formwork trolley system and construction method to solve the above-mentioned problems, thereby improving construction efficiency, ensuring construction safety, and promoting the mechanization of underground engineering.

[0007] To achieve the above objectives, the present invention provides the following solution: a detachable template trolley system, comprising a walking system, a support system, and a template system, wherein the bottom end of the support system is detachably connected to the top end of the walking system, and the template system is detachably connected to the top end and side wall of the support system;

[0008] The support system includes a first support, a second support, and a third support. The bottom ends of the first support, the second support, and the third support are detachably connected to the top end of the walking system. The side walls of the first support and the second support are detachably connected to the template system. The top end of the third support is detachably connected to the template system.

[0009] The template system includes a main template, active templates, and splicing templates.

[0010] Preferably, the walking system includes two parallel tracks, with a plurality of sleepers in contact at the bottom of the two tracks. The sleepers are evenly spaced along the length of the tracks. Two walking wheels are rolled at the top of each track, one of which is connected to a walking motor. The top of the walking wheel is detachably connected to the bottom of the first, second, and third supports.

[0011] Preferably, the template system includes the main template, the movable template is hinged to the bottom of the main template, and the splicing template is detachably connected to the top of the main template. The main template, the movable template, and the splicing template are detachably connected to the side wall of the first support.

[0012] Preferably, the template system includes a main template and a movable template, and the main template and the movable template are detachably connected to the side wall of the second support.

[0013] Preferably, the template system includes the main template and the splicing template, and the main template and the splicing template are detachably connected to the top of the third support.

[0014] A construction method for a detachable formwork trolley system includes the following steps:

[0015] S1. Measurement and positioning;

[0016] S2. Install the walking system;

[0017] S3. Assemble the first support, the second support, the third support, and the template system;

[0018] S4. Pouring construction;

[0019] S5. Dismantle the template system;

[0020] S6. Proceed to the next work cycle.

[0021] The present invention has the following technical effects:

[0022] This invention discloses a separable formwork trolley system suitable for the skip-section method of secondary lining construction in large-section tunnels, and provides its construction method. This formwork trolley system, based on the traditional integral formwork trolley, divides the integral formwork trolley into three parts: lower, upper, and arch. Through a rationally designed lifting system for each part, it can move independently within each pilot tunnel without removing the initial support, and then reassemble into a single unit for integrated operation at the predetermined position. Furthermore, the design of the joints between the formwork parts ensures construction quality, thereby achieving mechanized construction of secondary lining formwork engineering in large-section tunnels. Using the separable formwork trolley system to replace traditional construction methods can effectively improve construction efficiency and quality, and greatly reduce the construction risks of large-section tunnel projects. The formwork trolley designed and applied based on this method will provide guidance and reference for formwork engineering in large-section tunnels, offering good economic benefits and playing a significant role in promoting the mechanization of tunnel construction. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the cross-section of the side wall module of the trolley system;

[0025] Figure 2 This is a schematic diagram of the cross-section of the arched module of the trolley system;

[0026] Figure 3 This is a cross-sectional view of the walking system;

[0027] Figure 4 This is a schematic diagram of the cross-section of the walking system;

[0028] Figure 5 This is a schematic diagram of the lower cross section of the side wall of the support system;

[0029] Figure 6 This is a schematic diagram of the lower longitudinal section of the sidewall of the support system;

[0030] Figure 7 This is a schematic diagram of the upper cross section of the side wall of the support system;

[0031] Figure 8 This is a schematic diagram of the upper longitudinal section of the side wall of the support system;

[0032] Figure 9 This is a schematic diagram of the cross-section of the arch of the support system;

[0033] Figure 10 This is a schematic diagram of the longitudinal section of the arch of the support system;

[0034] Figure 11 This is a schematic diagram of the lower cross section of the side wall of the formwork system;

[0035] Figure 12 This is a diagram showing the single-sided flat tiling position of the lower part of the sidewall of the formwork system;

[0036] Figure 13 This is a schematic diagram of the upper cross section of the side wall of the template system;

[0037] Figure 14 This is a diagram showing the tiling position on one side of the upper part of the side wall of the template system;

[0038] Figure 15 This is a schematic diagram of the cross-section of the arch of the template system;

[0039] Figure 16 A diagram showing the tiling location of the arched formwork system;

[0040] Figure 17 This is a flowchart of the construction process.

[0041] The components include: 1. Walking system; 2. Support system; 3. Template system; 1-1. Walking wheels; 1-2. Track; 1-3. Sleeper; 1-4. Walking motor; 1-5. Beam support point; 2-1. Upper longitudinal beam; 2-2. Gantry lifting system; 2-3. Lower longitudinal beam; 2-4. Diagonal brace; 2-5. Gantry support frame; 2-6. Connecting beam; 2-7. Demolding system; 2-8. Counterweight; 2-9. River crossing support; 2-10. Top support; 2-11. Side support; 2-12. Working platform; 2-13. Hydraulic jack; 2-14. Top longitudinal beam support; 2-15. Adjusting screw; 2-16. Template support; 2-17. Gantry screw; 3-1. Main template; 3-2. Movable template; 3-3. Splicing template; 4. Working window; 5. Attached plate vibrator; 6. Grouting hole. Detailed Implementation

[0042] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0043] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0044] Reference Figure 1-17 The present invention discloses a detachable template trolley system, including a walking system 1, a support system 2, and a template system 3. The bottom end of the support system 2 is detachably connected to the top end of the walking system 1, and the template system 3 is detachably connected to the top end and side wall of the support system 2.

[0045] The support system 2 includes beam support points 1-5, upper longitudinal beam 2-1, gantry lifting system 2-2, lower longitudinal beam 2-3, diagonal brace 2-4, gantry support frame 2-5, connecting beam 2-6, demolding system 2-7, counterweight 2-8, river crossing support 2-9, top support 2-10, side support 2-11, working platform 2-12, hydraulic jack 2-13, top longitudinal beam support 2-14, adjusting screw 2-15, template support 2-16, gantry screw 2-17;

[0046] Template system 3 includes main template 3-1, activity template 3-2, and splicing template 3-3.

[0047] The scheme is further optimized. The walking system 1 includes two parallel tracks 1-2. Several sleepers 1-3 are arranged at the bottom of the two tracks 1-2. The sleepers 1-3 are arranged at equal intervals along the length of the tracks 1-2. Two walking wheels 1-1 are rolled at the top of each track 1-2. One of the walking wheels 1-1 is connected to a walking motor 1-4. The top of the walking wheel 1-1 is detachably connected to the bottom of the gantry lifting system 2-2.

[0048] Before installing the support system 2 and the template system 3, the sleepers 1-3 are laid out as required. Under the action of the traveling motor 1-4, the traveling wheels 1-1 are driven forward or backward to complete the traveling task of the trolley system. The traveling system 1 is the driving device for the traveling of the trolley system, and it is also the load-bearing component of the trolley system.

[0049] After sleepers 1-3 and track 1-2 are laid, the track gauge error shall be controlled within ±10mm; track 1-2 and sleepers 1-3 must be fixed with track spikes, and sleepers 1-3 shall be fixed laterally with angle steel or steel bars to prevent danger when the trolley moves; the spacing between sleepers 1-3 shall not exceed 500mm to prevent track 1-2 from being crushed.

[0050] The support system 2 is located in the middle of the trolley system. Its upper part supports the formwork system 3, and its lower part connects to the traveling system 1, serving the functions of force transmission and height adjustment. Depending on its location, it is divided into three parts: the lower part of the side wall, the upper part of the side wall, and the arch.

[0051] The template system 3 is a crucial component of the trolley, requiring its outer surface to be geometrically accurate, flat, smooth, and free of misalignments. Depending on its location, it is divided into three parts: the lower part of the side walls, the upper part of the side walls, and the arch.

[0052] Further optimizing the scheme, the support system 2 includes two lower longitudinal beams 2-3, which correspond vertically to two traveling wheels 1-1. Each lower longitudinal beam 2-3 has several beam support points 1-5 fixedly connected to its bottom end, with these support points 1-5 evenly spaced. The tops of the two lower longitudinal beams 2-3 are jointly and fixedly connected to several portal frame support frames 2-5, also evenly spaced. A portal frame lifting system 2-2 is fixedly connected to the outer sides of the portal frame support frames 2-5 at both ends. The tops of the portal frame support frames 2-5 are jointly and fixedly connected to several top longitudinal beam supports 2-14, arranged in two parallel rows. The top of each row of top longitudinal beam supports 2-14 is fixedly... The upper longitudinal beam 2-1 is fixedly connected. Several demolding systems 2-7 are fixedly connected to the top of the two upper longitudinal beams 2-1. The demolding systems 2-7 are evenly spaced. One end of the demolding system 2-7 is detachably connected to the template system 3. The other end of the demolding system 2-7 is fixedly connected to a side support 2-11. Several top supports 2-10 are fixedly connected to the top of the upper longitudinal beam 2-1. The top supports 2-10 are evenly spaced. One end of the top of the top support 2-10 is threadedly connected to an adjusting screw 2-15. The other end of the adjusting screw 2-15 is detachably connected to the template system 3. The lower longitudinal beam 2-3 is threadedly connected to one end of the adjusting screw 2-15. The other end of the adjusting screw 2-15 is detachably connected to the template system 3.

[0053] Furthermore, the portal frame 2-5 consists of a portal frame beam, columns and connecting plates, and is reinforced by diagonal braces 2-4 and connecting beams 2-6 to form a complete support system. The portal frame beam and columns are welded from steel plates, making them stable and reliable.

[0054] This is the support system 2 at the bottom of the side wall. The support points 1-5 under the beam are jacks, which are adjusted to retract when the trolley is moving and to extend after the trolley is in place, supporting the track 1-2, thus achieving stable positioning of the entire set of equipment. The upper longitudinal beam 2-1, lower longitudinal beam 2-3, and diagonal brace 2-4 are made of heavy-duty H-beams welded together. The lower longitudinal beam 2-3 transmits the force from the upper part of the trolley to the bottom, forming a complete force-bearing system.

[0055] The gantry lifting system 2-2 consists of hydraulic jacks and lifting limiters. The jacks are installed inside the limiters and bolted to the top of the traveling wheels 1-1. The lifting limiters are composed of two sections of square steel, with the lower section slightly smaller than the upper section and inserted inside it. A steel plate is welded to the top of the upper section to seal it. The jack base supports the top of the upper section. When the lifting jacks are in operation, the upper and lower sections of the square steel can only undergo relative vertical displacement, limiting the lateral displacement of the trolley during lifting and thus achieving stable lifting and lowering of the entire trolley. The gantry lifting system 2-2 can adjust the overall height of the template trolley via the jacks to facilitate trolley movement and make it suitable for tunnel cross-sections of various heights.

[0056] Furthermore, the upper part of the lower longitudinal beam 2-3 is threadedly connected to one end of a hydraulic jack 2-13, and the other end of the hydraulic jack 2-13 is detachably connected to the formwork system 3.

[0057] The demolding system 2-7 and hydraulic jack 2-13 are designed for the lifting and telescopic movement of the formwork system 3. Hydraulic jack 2-13 provides some support. The demolding system 2-7 consists of a jack and two nested layers of steel profiles. In the nested steel profiles, the inner steel profile is bolted to the formwork system 3, and sliding rails are laid between the steel profiles to allow relative sliding. The outer steel profile, near the central partition wall, is sealed with a welded steel plate, and a connecting plate is welded to the middle of the inner steel profile. The top of the jack is connected to the connecting plate, and the bottom is supported on the sealed bottom of the outer steel profile. By extending and retracting the jack within the demolding system 2-7, the inner steel profile slides smoothly. Working simultaneously with the hydraulic jack 2-13, the positioning and demolding of the upper formwork system 3 on the side wall can be achieved.

[0058] Furthermore, a counterweight 2-8 is provided on the outer side of the lower longitudinal beam 2-3 away from the formwork system 3, and several cross-river supports 2-9 are threadedly connected between the two lower longitudinal beams 2-3. A working platform 2-12 is provided on the side of the portal support frame 2-5 close to the formwork system 3.

[0059] Counterweight 2-8 is placed on the side of the lower longitudinal beam 2-3. Adjusting counterweight 2-8 ensures the balance of forces on both sides of the support system 2 at the bottom of the side wall. The counterweight 2-8 support is welded from angle steel and bolted to the portal frame 2-5. The upper part of counterweight 2-8 is fixed to the crossbeam of the portal frame 2-5 by a hand-operated hoist. Additional counterweight 2-8 supports and limiters can be added as needed. The river-crossing support 2-9 stabilizes the portal frame 2-5 and adjusts its width. The top support 2-10 and side support 2-11 function similarly to the beam support point 1-5, retracting during trolley movement and extending after the trolley is in place, supported by temporary partitions. The working platform 2-12 facilitates the placement and demolding of the formwork system 3. The adjusting screw 2-15 primarily adjusts the position of the formwork system 3 to achieve precise placement and demolding.

[0060] The scheme is further optimized. The template system 3 includes a main template 3-1, a movable template 3-2 hinged to the bottom of the main template 3-1, a splicing template 3-3 detachably connected to the top of the main template 3-1, a detachable connection between the main template 3-1 and the demolding system 2-7, an adjusting screw 2-15 threaded to the lower longitudinal beam 2-3 detachably connected to the movable template 3-2, and an adjusting screw 2-15 threaded to the top support 2-10 detachably connected to the splicing template 3-3.

[0061] This is the formwork system 3 at the bottom of the side wall. After the spliced ​​formwork 3-3 is in place, it is fixed to the main formwork 3-1 with bolts and steel sections. Horizontal and longitudinal beams are installed on the inner sides of the main formwork 3-1, movable formwork 3-2, and spliced ​​formwork 3-3, and are reinforced with angle steel to enhance their overall function.

[0062] The placement and dismantling of the main formwork 3-1 is hydraulic, primarily achieved through the demolding system 2-7 and hydraulic jacks 2-13. The movable formwork 3-2 and the spliced ​​formwork 3-3 are placed and dismantled manually, using adjusting screws 2-15 to adjust their positions. Only after demolding can the trolley be hydraulically positioned and dismantled. The movable formwork 3-2 and spliced ​​formwork 3-3 require additional on-site support and reinforcement. To ensure the quality of the sidewall pouring, the joint shape of the spliced ​​formwork 3-3 on the upper and lower sidewall formwork trolleys is specially treated, employing a Z-shaped interlocking joint to effectively prevent cement slurry leakage during concrete pouring.

[0063] The lower formwork system of the side wall has a total of 6 working windows. All grouting ports and trolley connections have been reinforced, and the joints with the trolley are tight to ensure the formation effect of the secondary lining. An attached plate vibrator is installed on the formwork trolley.

[0064] Further optimizing the scheme, the support system 2 includes two lower longitudinal beams 2-3, which correspond vertically to two traveling wheels 1-1. Each lower longitudinal beam 2-3 has several beam support points 1-5 fixedly connected to its bottom end, with these support points evenly spaced. Each lower longitudinal beam 2-3 has a gantry lifting system 2-2 fixedly connected to both ends. Each lower longitudinal beam 2-3 has several top longitudinal beam supports 2-14 fixedly connected to its top end, with these supports evenly spaced. The top of the beam support 2-14 is fixedly connected to the upper longitudinal beam 2-1. The tops of the two upper longitudinal beams 2-1 are fixedly connected to several template supports 2-16. The template supports 2-16 are evenly spaced. One end of the template support 2-16 is detachably connected to the template system 3. The other end of the template support 2-16 is fixedly connected to the side support 2-11. The side wall and bottom of the lower longitudinal beam 2-3 are respectively threaded with one end of the adjusting screw 2-15. The other end of the adjusting screw 2-15 is detachably connected to the template system 3.

[0065] This is the upper support system 2 of the side wall. The functions and working principles of its components are mostly the same as the corresponding parts of the lower support system 2 of the side wall. The difference is that, due to the lower height of the upper support system 2, the top longitudinal beam support 2-14 is directly installed on top of the lower longitudinal beam 2-3, excluding the portal frame 2-5 and the diagonal braces 2-4 and connecting beams 2-6 connecting the portal frame 2-5, and there is no need to set up a working platform 2-12. The placement and dismantling of the formwork system 3 are completed by the portal frame lifting system 2-2, therefore a separate dismantling system is not required. Furthermore, this support system 2 has a small eccentricity and is in an axially stressed state, eliminating the need for a counterweight 2-8.

[0066] The formwork support 2-16 consists of a lower I-beam and four reinforcing ribs welded parallel to the I-beam. The I-beam is fixed to the upper longitudinal beam 2-1. The formwork support 2-16 is connected to the formwork system 3 by bolts through angle steel.

[0067] The scheme is further optimized. The template system 3 includes a main template 3-1, a movable template 3-2 is hinged to the bottom of the main template 3-1, the template support 2-16 is detachably connected to the main template 3-1, and two adjusting screws 2-15 are detachably connected to the movable template 3-2.

[0068] This is the upper formwork system 3 of the side wall. The connection method and working principle of each part are mostly the same as the corresponding parts of the lower formwork system 3 of the side wall. The difference is that the main formwork 3-1 is positioned and dismantled through the gantry lifting system 2-2; the movable formwork 3-2 is positioned and dismantled by manual adjustment in conjunction with hydraulic jacks 2-13.

[0069] Further optimization of the scheme: The support system 2 includes two lower longitudinal beams 2-3, which correspond to two traveling wheels 1-1 respectively. Each lower longitudinal beam 2-3 has several beam support points 1-5 fixedly connected to its bottom end. The beam support points 1-5 are evenly spaced. The tops of the two lower longitudinal beams 2-3 are fixedly connected to several portal frame support frames 2-5. The portal frame support frames 2-5 are evenly spaced. The outer sides of the portal frame support frames 2-5 at both ends are fixedly connected to a portal frame lifting system 2-2. A portal frame screw 2-17 is threaded between the tops of any two portal frame support frames 2-5. The tops of the portal frame support frames 2-5 are fixedly connected to two parallel upper longitudinal beams 2-1. The upper longitudinal beams 2-1 abut against the template system 3. One end of an adjusting screw 2-15 is threadedly connected to both sides of the portal frame support frame 2-5. The other end of the adjusting screw 2-15 is detachably connected to the template system 3.

[0070] This is the arch support system 2. The functions and working principles of its components are mostly the same as the corresponding parts of the support systems 2 at the bottom and top of the side walls. The difference lies in that the upper longitudinal beam 2-1 is directly fixed to the top of the crossbeam of the portal frame 2-5, and the formwork system 3 is directly fixed to the upper part of the upper longitudinal beam 2-1. Since the arch formwork system 3 is located directly above the support system 2, its placement and demolding are achieved by raising and lowering the support system 2 through the portal frame lifting system 2-2. Therefore, there is no need to set up a demolding system 2-7 and hydraulic jacks 2-13. The hydraulic cylinder of the portal frame lifting system 2-2 of the arch support system 2 mainly serves a supporting function. To prevent leakage and sinking, a mechanical lock is installed on the cylinder. The function of the portal screw 2-17 is to adjust the width of the support system 2 together with the cross-river support 2-9.

[0071] The scheme is further optimized. The template system 3 includes a main template 3-1, with splicing templates 3-3 detachably connected to both ends of the main template 3-1. The tops of the two upper longitudinal beams 2-1 abut against the main template 3-1, and the adjusting screw 2-15 is detachably connected to the splicing template 3-3.

[0072] This is the arch formwork system 3. The connection methods and working principles of its various parts are mostly the same as those of the corresponding parts in the lower part of the side wall formwork system 3. The difference lies in that the placement and dismantling of the main formwork 3-1 is achieved through the gantry lifting system 2-2. The arch formwork system 3 is located directly above its support system 2. When the trolley is moving, it is only necessary to lower the trolley height and retract the side panels; therefore, a movable formwork 3-2 is not required. The arch formwork system 3 has three grouting holes 6 at the front, middle, and rear of the arch centerline.

[0073] A construction method for a detachable formwork trolley system includes the following steps:

[0074] S1. Measurement and positioning;

[0075] Measurement and positioning are performed inside the construction tunnel or pilot tunnel.

[0076] S2. Install walking system 1;

[0077] The laying of track 1-2 and sleepers 1-3 must meet the requirements, and the track gauge error after laying must be controlled within ±10mm; track 1-2 and sleepers 1-3 must be fixed with track spikes, and sleepers 1-3 must be fixed laterally with angle steel or steel bars to prevent danger when the trolley moves; the spacing between sleepers 1-3 must not exceed 500mm to prevent track 1-2 from being crushed.

[0078] S3, Assembly support system 2 and template system 3;

[0079] After sleepers 1-3 and rails 1-2 are in place, assemble the frame and connect the traveling motor 1-4 at the section of the side wall where the reinforcing steel is not tied, so as to install the formwork system 3. After the trial assembly of the formwork system 3 is completed, lift it with a hand hoist or other hoisting equipment, and place the frame of the traveling trolley in place to install the formwork system 3.

[0080] After the lower support system 2 is installed, the formwork trolley is positioned, followed by the installation, debugging, and positioning of other components. The upper support system 2 is installed and positioned following the same process as the lower support system 2. The connection nodes between the upper and lower support systems 2 are then fixed and adjusted to ensure a smooth connection of the formwork system 3. After assembly, the edge positions of the support system 2 are checked to ensure the dimensions of the secondary lining structure. The arch support system 2 is installed following the same process as the lower support system 2. The connection nodes between the arch support system 2 and the upper support system 2 are then fixed and adjusted to ensure a smooth connection of the formwork system 3. After assembly, the edge positions of the support system 2 are checked to ensure the dimensions of the secondary lining structure.

[0081] Move the trolley forward to the lining section and repeat the back-and-forth motion several times to loosen the trolley structure. Stop it in the correct lining position, turn off the travel motors 1-4, and insert wooden wedges or use wheel stops at the travel wheels 1-1 to prevent slippage or displacement of the frame due to eccentric forces during lining, which could cause formwork runaway or bursting. Apply release agent to the outer surface of the formwork system 3, install end plates, and add necessary supports.

[0082] Tighten the spiral support legs under the lower longitudinal beams 2-3 to ensure the base plate rests on a solid foundation. Remove all hinge pins from the side mold support screws and template sides. Start the hydraulic pump and operate the lifting cylinder to raise the trolley to the designed arch elevation. Operate the self-aligning cylinder to fine-tune the trolley to the accurate position. If the cylinders move asynchronously, lock the screw closest to one cylinder and continue operating the valve to extend the other cylinders in the same row. Screws can be used for minor adjustments. After the side molds reach the designed dimensions, install all side mold screws and ensure they are tightened. After the trolley is in place, the hydraulic pump power must be turned off to prevent accidental operation of the valve group handles, which could deform the trolley structure or damage the hydraulic cylinders.

[0083] S4. Pouring construction;

[0084] Injection is carried out through injection hole 6, and special attention is paid to sealing during arch construction, and the outline radius of arch support system 2 is extended outward by 30mm.

[0085] S5. Remove the formwork system 3;

[0086] Once the curing period is complete, demolding can begin. Start the hydraulic pump, operate the manual directional valve handle of the side mold to extend the cylinder slightly, loosen the lead screw, and remove all lead screws from the side mold.

[0087] Demolding the side mold: Operate the side mold cylinder to retract the side mold and detach it from the molded concrete surface. The cylinder must retract in stages; never force demolding in one go. The cylinder retraction stroke is 250mm to 300mm.

[0088] Demolding the top mold: Operate the main hydraulic cylinder to retract the top mold, detaching it from the molded concrete surface. The cylinder retraction stroke is 200mm~250mm.

[0089] S6. Proceed to the next work cycle.

[0090] Rotate the lower spiral support legs of the lower longitudinal beam 2-3, remove the wooden wedges or wheel stops at the traveling wheel 1-1, operate the trolley to move forward to the next lining position, and start the next work cycle.

[0091] Key points of this invention:

[0092] 1. Make full use of the splitting method to improve the traditional integral formwork trolley into a separate formwork trolley system that can travel separately in each pilot tunnel and can be used as a whole after being in place, so as to adapt to the skip-section method of secondary lining construction of large cross-section tunnels.

[0093] 2. The lifting system of each formwork trolley was reasonably designed to ensure safe movement within each guide hole. At the same time, a Z-shaped joint was used at the joint of the upper and lower formwork trolleys to ensure construction quality.

[0094] 3. The separate formwork trolley system realizes the automation of the construction of large-section tunnel arch wall formwork. Due to its flexibility and speed, it can save construction time, reduce risks and improve construction quality, and solve the impact of dismantling and support construction on the safety of tunnel construction.

[0095] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0096] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A detachable template trolley system, characterized in that, It includes a walking system (1), a support system (2), and a template system (3). The bottom end of the support system (2) is detachably connected to the top end of the walking system (1), and the template system (3) is detachably connected to the top end and side wall of the support system (2). The support system (2) includes a first support, a second support, and a third support. The bottom ends of the first support, the second support, and the third support are detachably connected to the top end of the walking system (1). The side walls of the first support and the second support are detachably connected to the template system (3). The top end of the third support is detachably connected to the template system (3). The template system (3) includes a main template (3-1), an active template (3-2), and a splicing template (3-3); The walking system (1) includes two parallel tracks (1-2), with a number of sleepers (1-3) in contact at the bottom of the two tracks (1-2). The sleepers (1-3) are evenly spaced along the length of the tracks (1-2). Two walking wheels (1-1) are rolled at the top of each track (1-2). One of the walking wheels (1-1) is connected to a walking motor (1-4). The top of the walking wheel (1-1) is detachably connected to the bottom of the first support, the second support, and the third support. The support system (2) at the bottom of the side wall includes two lower longitudinal beams (2-3), which correspond to two traveling wheels (1-1) respectively. Each lower longitudinal beam (2-3) has several beam support points (1-5) fixedly connected to its bottom end. These support points (1-5) are evenly spaced. Several portal frame support frames (2-5) are fixedly connected to the top of both lower longitudinal beams (2-3). These portal frame support frames (2-5) are evenly spaced. A portal frame lifting system (2-2) is fixedly connected to the outer side of the portal frame support frames (2-5) at both ends. Several top longitudinal beam supports (2-14) are fixedly connected to the top of the portal frame support frames (2-5). These top longitudinal beam supports (2-14) are arranged in two parallel rows. Each row of top longitudinal beam supports (2-14) is fixedly connected to the top of... The upper longitudinal beam (2-1) has several demolding systems (2-7) fixedly connected to the top of the two upper longitudinal beams (2-1). The demolding systems (2-7) are evenly spaced. One end of the demolding system (2-7) is detachably connected to the template system (3). The other end of the demolding system (2-7) is fixedly connected to a side support (2-11). The top of the upper longitudinal beam (2-1) has several top supports (2-10) fixedly connected to the top. The top supports (2-10) are evenly spaced. The top of the top support (2-10) is threadedly connected to one end of an adjusting screw (2-15). The other end of the adjusting screw (2-15) is detachably connected to the template system (3). The lower longitudinal beam (2-3) is threadedly connected to one end of an adjusting screw (2-15). The other end of the adjusting screw (2-15) is detachably connected to the template system (3). The upper support system (2) of the side wall includes two lower longitudinal beams (2-3), which correspond to two traveling wheels (1-1) respectively. Each lower longitudinal beam (2-3) has several beam support points (1-5) fixedly connected to its bottom end. The beam support points (1-5) are evenly spaced. Each lower longitudinal beam (2-3) has a gantry lifting system (2-2) fixedly connected to both ends. Each lower longitudinal beam (2-3) has several top longitudinal beam supports (2-14) fixedly connected to its top end. The top longitudinal beam supports (2-14) are evenly spaced. (2-14) The top of the two upper longitudinal beams (2-1) are fixedly connected to the upper longitudinal beams (2-1). The top of the two upper longitudinal beams (2-1) are fixedly connected to several template supports (2-16). The template supports (2-16) are evenly spaced. One end of the template support (2-16) is detachably connected to the template system (3). The other end of the template support (2-16) is fixedly connected to the side support (2-11). The side wall and bottom of the lower longitudinal beam (2-3) are respectively threaded with one end of the adjusting screw (2-15). The other end of the adjusting screw (2-15) is detachably connected to the template system (3). The arch support system (2) includes two lower longitudinal beams (2-3), which correspond to two traveling wheels (1-1) respectively. Each lower longitudinal beam (2-3) has several beam support points (1-5) fixedly connected to its bottom end. These support points (1-5) are evenly spaced. The tops of the two lower longitudinal beams (2-3) are jointly fixedly connected to several portal frame supports (2-5), which are also evenly spaced. The portal frame supports (2-5) at both ends are positioned on their outer sides... A gantry lifting system (2-2) is fixedly connected to each other. A gantry screw (2-17) is threaded between the tops of any two gantry support frames (2-5). Two parallel upper longitudinal beams (2-1) are fixedly connected to the tops of several gantry support frames (2-5). The upper longitudinal beams (2-1) abut against the template system (3). One end of an adjusting screw (2-15) is threaded to each side of the gantry support frame (2-5). The other end of the adjusting screw (2-15) is detachably connected to the template system (3).

2. The detachable template trolley system according to claim 1, characterized in that, The template system (3) includes the main template (3-1), the bottom end of the main template (3-1) is hinged to the movable template (3-2), the top end of the main template (3-1) is detachably connected to the splicing template (3-3), and the main template (3-1), the movable template (3-2), and the splicing template (3-3) are detachably connected to the side wall of the first support.

3. The detachable template trolley system according to claim 1, characterized in that, The template system (3) includes the main template (3-1) and the movable template (3-2), and the main template (3-1) and the movable template (3-2) are detachably connected to the side wall of the second support.

4. The detachable template trolley system according to claim 1, characterized in that, The template system (3) includes the main template (3-1) and the splicing template (3-3), and the main template (3-1) and the splicing template (3-3) are detachably connected to the top of the third support.

5. A construction method for a detachable formwork trolley system as described in any one of claims 1-4, characterized in that, Includes the following steps: S1. Measurement and positioning; S2. Install the walking system (1); S3. Assemble the first support, the second support, the third support and the template system (3); S4. Pouring construction; S5. Dismantle the template system (3); S6. Proceed to the next work cycle.

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