An automatic concrete casting system and its construction method

Abstract

The application discloses a kind of concrete automatic casting system and its construction method, the pouring system includes formwork, track, walking mechanical device and controller.The track is set on the top of the formwork, the walking mechanical device includes walking mechanism and mechanical arm;The telescopic cantilever rod is set on the walking mechanical device;The range finder is set in the telescopic cantilever rod end, for measuring the concrete pouring height in formwork;The position of the controller in pre-set concrete pouring section, concrete pouring parameter.This pouring system can measure the concrete pouring height in formwork by range finder, and compare with the pre-set concrete each layer pouring height, final pouring height in controller, determine whether concrete moves to next pouring section, to control walking mechanism walking, realize concrete automatic pouring, improve the degree of automation of construction, and make concrete slurry evenly distributed, effectively guarantee concrete construction quality.

Description

TECHNICAL FIELD

[0001] The present application relates to a kind of concrete automatic casting system and its construction method on site, belong to concrete construction technical field. BACKGROUND

[0002] At present, large volume concrete formwork mainly has integral large formwork, combined large formwork, these formwork supports well, plus large volume concrete inside pre-placed steel column, bound a large number of threaded steel bars and stirrups, so that the visual field of site pouring concrete is dim, site pouring usually relies on visual and experience to judge the concrete distribution in the enclosed formwork cavity, then decide whether to move the distribution port, but the concrete flow in the formwork is difficult to judge whether uniform, and the specific position of non-uniform is also unclear, workers can only pour route operation according to experience and feeling, until obvious push material appears to move, or vibrating rod disperses, although self-compacting concrete can be used, but in the face of dense reinforcement, if not handled in time, it will lead to material stacking, hollowing, and affect the quality of concrete later period. When pouring on site, large volume concrete pouring quantity is large and needs continuous uninterrupted construction, manual pouring generally adopts two shifts, three shifts form, and will support scaffold operation platform around pouring formwork, workload is large, there is a large amount of high-altitude operation, and the space arrangement of site is small, and the working environment is poor.

[0003] Therefore, it is necessary to develop a kind of concrete automatic casting system and its construction method on site. SUMMARY

[0004] The present application provides a kind of concrete automatic casting system and its construction method on site, to solve the problems of large volume concrete pouring, such as large pouring strength, difficult to continuous construction, and workers difficult to determine when to move distribution pipe.

[0005] To solve the above technical problems, the present application includes the following technical solutions:

[0006] A kind of concrete automatic casting system on site, the concrete automatic casting system on site includes formwork, track, walking mechanical device and controller;

[0007] The track is arranged on the top of the formwork, and is arranged along the length direction of formwork;

[0008] The walking mechanical device includes walking mechanism and mechanical arm;The walking mechanism can walk along the track, and the mechanical arm is used to support distribution pipe;

[0009] The telescopic cantilever rod is arranged on the walking mechanical device;The range finder is arranged at the end of the telescopic cantilever rod, and is used to measure the pouring height of concrete in formwork;

[0010] The controller is internally preset with the position of the concrete pouring section, the final pouring height H of the concrete Z , the pouring layer number M, the pouring height L of each layer, and the concrete height difference control parameter ΔH in the formwork; and the walking mechanism automatically walks and pours the concrete according to the pouring height measured by the range finder.

[0011] Further, the formwork is provided with a corner, the track includes a first straight track section, a second straight track section and a corner connecting section; the corner connecting section is arranged at the corner of the formwork, and the first straight track section and the second straight track section are arranged on the formwork on the two sides of the corner connecting section respectively;

[0012] A rotating mechanism is arranged below the corner connecting section, and when the walking mechanism moves to the corner connecting section through the first straight track section, the rotating mechanism can drive the corner connecting section and the walking mechanism to rotate, so that the walking mechanism rotates to the direction of the second straight track section, thereby enabling the walking mechanism to pass through the corner of the formwork.

[0013] Further, a 5G camera is arranged on the walking mechanism to upload information such as the concrete distribution situation and the position of the distribution machine to a remote monitoring terminal.

[0014] Correspondingly, the application also provides a construction method of the concrete field automatic pouring system, which includes the following steps:

[0015] Step one: hoist the formwork into position and install and fix it, install the track and the walking mechanism on the top of the formwork, fix the distribution pipe at one end of the walking mechanism, install the telescopic cantilever rod on the walking device, and arrange the range finder at the end of the telescopic cantilever rod;

[0016] Step two: divide the pouring area into a plurality of pouring sections, and preset the position of the concrete pouring section, the final pouring height H Z , the pouring layer number M, the pouring height L of each layer, and the concrete height difference control parameter ΔH in the controller;

[0017] Step three: control the walking mechanism to walk along the track, and control the telescopic cantilever rod to extend and retract and measure the pouring height of the concrete by the range finder; control the walking speed of the walking mechanism at the corresponding position according to the elevation measured by the range finder, and control the distribution amount of the concrete, so that the pouring height difference of the concrete meets the requirements;

[0018] Step four: after the mth layer of one pouring section is poured, the walking mechanism is controlled by the controller to walk to the next pouring section, and step three is repeated to complete the pouring of the mth layer of concrete, until all the pouring areas are poured to the mth layer, where m = 1, 2, …, M;

[0019] Step five: when the concrete in all the pouring sections is poured to H Z , the construction is completed.

[0020] Further, in step three, the controller controls the walking mechanism to walk along the track and pour concrete, and the mechanical arm controls the movement of the distribution pipe to pour in an S-shaped track; when reaching the boundary of the pouring section, the controller controls the walking mechanism to walk in reverse, and the mechanical arm controls the movement of the distribution pipe to pour in a reverse S-shaped track;

[0021] One S-shaped pouring path and one reverse S-shaped pouring path form a complete path; the pouring process of each layer of concrete includes one or more complete paths.

[0022] Further, the formwork is provided with a corner, the track includes a first straight track section, a second straight track section and a corner connecting section, the corner connecting section is arranged at the corner of the formwork, the first straight track section and the second straight track section are arranged on the formwork on the two sides of the corner connecting section respectively, and a rotating mechanism is arranged below the corner connecting section;

[0023] In step four, when the controller controls the walking mechanism to walk to the next pouring section and encounters a formwork corner, the walking mechanism walks along the first straight track section to the corner connecting section, is braked and clamped to the corner connecting section, the rotating mechanism can drive the corner connecting section and the walking mechanism to rotate together, so that the walking mechanism is rotated to the direction of the second straight track section, and the walking mechanism is started again to walk along the second straight track section.

[0024] Compared with the prior art, the concrete field automatic pouring system has the following advantages and positive effects: the concrete field automatic pouring system can measure the pouring height of the concrete in the formwork by the range finder, compare the pouring height with the preset pouring height of each layer of concrete and the final pouring height in the controller, determine whether the concrete moves to the next pouring section, control the walking mechanism to walk and realize automatic pouring of the concrete. The range finder is arranged on the telescopic cantilever rod, can form a wave-shaped monitoring path, can make the measurement accuracy meet the construction requirements by adjusting the wavelength of the wave shape, the concrete field automatic pouring system has simple structure and convenient operation, can be assembled on site, can realize continuous automatic pouring of the concrete on site, improves the degree of automation of construction, greatly reduces the labor intensity on site, makes the concrete slurry uniformly distributed, effectively guarantees the construction quality of the concrete and improves the construction efficiency on site. BRIEF DESCRIPTION OF DRAWINGS

[0025] Figure 1 FIG. 1 is a structural schematic view of a concrete field automatic pouring system in an embodiment of the present application;

[0026] Figure 2 FIG. 2 is a structural schematic view of a track and a U-shaped buckle provided in an embodiment of the present application;

[0027] Figure 3This is a schematic diagram of the guide rail structure at the corner of the template provided in an embodiment of the present invention.

[0028] The numbers in the diagram are as follows:

[0029] 1- Fabric tube;

[0030] 10-Template;

[0031] 20-Rail; 21-U-shaped fastener; 22-First straight rail section; 23-Second straight rail section; 24-Corner connection section; 25-Rotating mechanism;

[0032] 30-Walking mechanical device; 31-Walking mechanism; 32-Mechanical arm; 33-Hydraulic clamp;

[0033] 40 - Telescopic cantilever rod; 41 - Rangefinder. Detailed Implementation

[0034] The following detailed description, in conjunction with the accompanying drawings and specific embodiments, provides a more detailed explanation of the automatic on-site concrete pouring system and its construction method provided by the present invention. The advantages and features of the present invention will become clearer from the following description. It should be noted that the accompanying drawings are all in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the present invention.

[0035] Example 1

[0036] like Figure 1 As shown, the automatic concrete pouring system provided in this embodiment includes a formwork 10, a track 20, a walking mechanical device 30, and a controller.

[0037] like Figure 1 As shown, the track 20 is disposed on the top of the template 10 and is arranged along the length of the template 10. Typically, the template includes a panel, a back rib, and a frame, and the track 20 is fixed to the upper frame of the template 10. Furthermore, in conjunction with... Figure 1 and Figure 2 As shown, a U-shaped fastener 21 is provided below the track 20. The U-shaped fastener 21 is fastened to the top of the template 10, which enables the track 20 to be quickly installed and fixed. The U-shaped fastener 21 can be connected to the top of the template 10 by bolts or by direct welding.

[0038] like Figure 1As shown, the walking mechanical device 30 includes a walking mechanism 31 and a robotic arm 32. The walking mechanism 31 can travel along the track 20, and the robotic arm 32 is used to support the concrete placing pipe 1. A telescopic cantilever rod 40 is provided on the walking mechanical device 30, and a rangefinder 41 is provided at the end of the telescopic cantilever rod 40. The rangefinder 41 is used to measure the concrete pouring height inside the template 10. The extension and retraction of the telescopic cantilever rod can adjust the measuring point position of the rangefinder 41. The extension and retraction of the telescopic cantilever rod, combined with the travel of the walking mechanism 31 along the track 20, can form a waveform measuring point. During concrete pouring, the walking mechanism 31 travels relatively slowly; controlling the extension and retraction speed of the telescopic cantilever rod can adjust the wavelength of the waveform, making the measurement more accurate. For example, the cross-section of the track 20 is T-shaped or I-shaped. The walking mechanism includes a drive motor, a transmission mechanism, and a roller assembly. The roller assembly can be clip-on wheels, which are snapped onto the flange plate of the track. The drive motor drives the roller assembly to move along the track through the transmission mechanism, thereby causing the walking mechanical device to move along the track. The snap-fit ​​method between the roller assembly and the flange plate can be achieved using existing technology, and will not be elaborated here. The robotic arm adopts an existing multi-degree-of-freedom robotic arm. A hydraulic clamp is set at the front end of the robotic arm to hold the fabric tube 1. The bottom end of the fabric tube 1 can be equipped with an elephant trunk head to facilitate fabric placement.

[0039] The controller presets the location of the concrete pouring section and the final concrete pouring height H. Z The controller controls the number of pouring layers (M), the pouring height of each layer (L), and the concrete height difference within the formwork 10 (ΔH). Based on the pouring height measured by the rangefinder 41, the walking mechanism 31 is controlled to automatically move and pour concrete. The controller is used to collect the concrete pouring height H1 measured by the rangefinder 41 and calculate the average pouring height H. p When H p When L is reached, the controller controls the walking mechanism 31 to travel along the track 20 to the next pouring section to pour concrete; when H of all sections is reached... p All reach H Z At that time, the concrete pouring was completed.

[0040] The concrete automatic pouring system provided by the embodiment can measure the pouring height of the concrete in the formwork 10 through the range finder 41, compare the pouring height with the preset pouring height of each layer of the concrete and the final pouring height in the controller, determine whether the concrete moves to the next pouring section, control the walking mechanism 31 to walk, and realize automatic pouring of the concrete. The range finder 41 is arranged on the telescopic cantilever rod, can form a wave-shaped monitoring path, and can make the measurement accuracy meet the construction requirements by adjusting the wavelength of the wave. The concrete automatic pouring system has simple structure, is convenient to operate, can be assembled on site, can realize continuous automatic pouring of the concrete on site, improves the degree of automation of construction, greatly reduces the labor intensity on site, makes the concrete slurry uniformly distributed, effectively guarantees the construction quality of the concrete, and improves the construction efficiency on site.

[0041] In one specific embodiment, the formwork 10 is provided with a corner, the track 20 includes a first straight track section 22, a second straight track section 23 and a corner connecting section 24. The corner connecting section 24 is arranged at the corner of the formwork 10, and the first straight track section 22 and the second straight track section 23 are arranged on the formwork 10 on the two sides of the corner connecting section 24 respectively. A rotating mechanism 25 is arranged below the corner connecting section 24. When the walking mechanism 31 moves to the corner connecting section 24 through the first straight track section 22, the rotating mechanism 25 can drive the corner connecting section 24 and the walking mechanism 30 to rotate, so that the walking mechanism 31 rotates to the direction of the second straight track section 23, thereby enabling the walking mechanism 31 to pass through the corner of the formwork 10.

[0042] In one specific embodiment, a 5G camera is arranged on the walking mechanism 30, information such as the concrete distribution situation and the position of the distribution machine is uploaded to a remote monitoring terminal, the on-site situation can be remotely and real-timely viewed, and the safety of the system is improved.

[0043] Embodiment Two

[0044] The construction method of the concrete automatic pouring system provided by the embodiment is combined with the concrete automatic pouring system provided by the embodiment one. Figures 1 to 3 The construction method is further described in the embodiment one. The construction method includes the following steps.

[0045] Step one, hoist the formwork 10 into position, install and fix, install the track 20 and the walking mechanism 30 on the top of the formwork 10, fix the distribution pipe 1 at one end of the walking mechanism 30, install the telescopic cantilever rod 40 on the walking mechanism, and arrange the range finder 41 at the end of the telescopic cantilever rod 40;

[0046] Step two, divide the pouring area into a plurality of pouring sections, set the positions (start point and end point positions) of the pouring sections and the final pouring height H Z, the pouring layer number M, the pouring height L of each layer, and the concrete height difference control parameter AH in the formwork 10;

[0047] Step three, the controller controls the walking mechanism 31 to walk along the track 20, the telescopic cantilever rod 40 is telescopic and the concrete pouring height is measured by the range finder 41; the walking speed of the walking mechanism 31 at the corresponding position is controlled according to the elevation measured by the range finder 41, the concrete distribution quantity is controlled, and the concrete pouring height difference meets the requirements;

[0048] Step four, after the mth layer of one pouring section is completed, the controller controls the walking mechanical device 30 to walk to the next pouring section, and the mth layer of concrete pouring is completed by repeating step three, until all pouring areas are poured to the mth layer, wherein m = 1, 2, …, M;

[0049] Step five, when the concrete of all pouring sections is poured to H Z , the construction is completed.

[0050] In one embodiment, in step three, the controller controls the walking mechanism 31 to walk along the track 20 and pour concrete, and the mechanical arm 32 controls the movement of the distribution pipe 1 to pour in an S-shaped trajectory; when reaching the boundary of the pouring section, the controller controls the walking mechanism 31 to walk in the opposite direction, and the mechanical arm 32 controls the movement of the distribution pipe 1 to pour in a reverse S-shaped trajectory. Each layer of concrete pouring process at least includes an S-shaped pouring path and a reverse S-shaped pouring path, which is easy to control the concrete height difference after the concrete flows.

[0051] In one embodiment, the formwork 10 is provided with a corner, the track 20 includes a first straight rail section 22, a second straight rail section 23 and a corner connecting section 24, the corner connecting section 24 is arranged at the corner of the formwork 10, the first straight rail section 22 and the second straight rail section 23 are arranged on the formwork 10 on both sides of the corner connecting section 24 respectively, and the corner connecting section 24 is provided with a rotating mechanism 25 below. In step four, when the controller controls the walking mechanical device 30 to walk to the next pouring section and encounters the corner of the formwork 10, the walking mechanism 31 walks to the corner connecting section 24 along the first straight rail section 22, stops and clamps the corner connecting section 24, the rotating mechanism 25 can drive the corner connecting section 24 and the walking mechanical device 30 to rotate together, so that the walking mechanism 31 rotates to the direction of the second straight rail section 23, and the walking mechanism 31 is started again to walk along the second straight rail section 23.

[0052] The technical features of the above embodiments can be combined in any way. In order to make the description simple, not all possible combinations of the technical features in the above embodiments are described, however, as long as the combinations of the technical features do not exist contradictory, they should be considered as the scope of the present disclosure.

[0053] The above embodiments only express several implementation manners of the present application, and the description is more specific and detailed, but it should not be understood as a limitation on the scope of the patent. It should be noted that for ordinary skilled persons in the art, without departing from the concept of the present application, several modifications and improvements can be made, which are within the scope of protection of the present application. Therefore, the protection scope of the patent of the present application should be subject to the appended claims.

Claims

1. A concrete automatic casting system in situ, characterized in that, the concrete automatic casting system in situ comprises a formwork, a track, a walking mechanical device and a controller; the track is arranged on the top of the formwork and along the length direction of the formwork; the walking mechanical device comprises a walking mechanism and a mechanical arm; the walking mechanism can walk along the track, and the mechanical arm is used for supporting a placing pipe; a telescopic cantilever rod is arranged on the walking mechanical device; a range finder is arranged at the end of the telescopic cantilever rod and used for measuring the casting height of concrete in the formwork; the telescopic cantilever rod is telescopic and stacked with the walking mechanism to walk along the track, and can form a wave-shaped measuring point; when the concrete is cast, the telescopic speed of the telescopic cantilever rod can be controlled to adjust the wavelength of the wave shape, so that the measurement is more accurate; The controller presets the location of the concrete pouring section and the final concrete pouring height H. Z The system includes parameters such as the number of pouring layers (M), the pouring height of each layer (L), and the concrete height difference control parameter ΔH within the formwork. Based on the pouring height measured by the rangefinder, the system controls the walking mechanism to automatically move and pour concrete. The controller is used to collect the concrete pouring height measured by the rangefinder and calculate the average pouring height H. p When H p When L is reached, the controller controls the walking mechanism to move along the track to the next pouring section to pour concrete; when H of all sections is reached... p All reach H Z At that time, the concrete pouring was completed.

2. The concrete automatic casting system in situ according to claim 1, characterized in that, the formwork is provided with a corner, and the track comprises a first straight track section, a second straight track section and a corner connecting section; the corner connecting section is arranged at the corner of the formwork, and the first straight track section and the second straight track section are arranged on the formwork on the two sides of the corner connecting section respectively; a rotating mechanism is arranged below the corner connecting section; when the walking mechanism moves to the corner connecting section through the first straight track section, the rotating mechanism can drive the corner connecting section and the walking mechanical device to rotate, so that the walking mechanism is rotated to the direction of the second straight track section, thereby making the walking mechanism pass through the corner of the formwork.

3. The concrete automatic casting system in situ according to claim 1, characterized in that, a 5G camera is arranged on the walking mechanical device, and the concrete placing condition and the position information of the placing machine are uploaded to a remote monitoring terminal.

4. A method of constructing a concrete on-site automatic pouring system as claimed in claim 1, characterized in that, including the following steps: Step one, hoist the formwork into place and install and fix it, install the track and the walking mechanical device on the top of the formwork, fix the placing pipe at one end of the walking mechanical device, install the telescopic cantilever rod on the walking device, and arrange the range finder at the end of the telescopic cantilever rod; Step two, the pouring area is divided into several pouring sections, the controller is provided with the position of the concrete pouring section, the final pouring height H Z , the pouring layer number M, the pouring height L of each layer, and the concrete height difference control parameter ΔH in the formwork. Step three, the controller controls the walking mechanism to walk along the track, the telescopic cantilever rod is telescopic, and the range finder measures the concrete casting height; the walking speed of the walking mechanism at the corresponding position is controlled according to the elevation measured by the range finder, the placing amount of concrete is controlled, and the casting height difference of the concrete meets the requirements; Step four, after the mth layer of one casting section is completed, the controller controls the walking mechanical device to walk to the next casting section, and repeats step three to complete the mth layer of concrete casting, until all casting areas are cast to the mth layer, wherein m = 1, 2, …, M; Step five, the concrete of all pouring sections is poured to H Z when the construction is completed.

5. The construction method of the concrete automatic casting system in situ according to claim 4, characterized in that, in step three, during the process that the controller controls the walking mechanism to walk along the track and cast the concrete, the mechanical arm controls the placing pipe to move, and the placing is performed in an S-shaped track; when reaching the boundary of the casting section, the controller controls the walking mechanism to walk reversely, the mechanical arm controls the placing pipe to move, and the placing is performed in a reverse S-shaped track; one S-shaped casting path and one reverse S-shaped casting path form a complete path; the concrete casting process of each layer includes one or more complete paths.

6. The construction method of the concrete automatic casting system on site according to claim 4, wherein the formwork is provided with a corner, the track comprises a first straight track section, a second straight track section and a corner connecting section, the corner connecting section is arranged at the corner of the formwork, the first straight track section and the second straight track section are arranged on the formwork on two sides of the corner connecting section respectively, and a rotating mechanism is arranged below the corner connecting section. In step four, when the controller controls the walking mechanism to walk to the next pouring section and encounters a corner of the formwork, the walking mechanism walks along the first straight track section to the corner connecting section, is braked and clamped to the corner connecting section, the rotating mechanism can drive the corner connecting section and the walking mechanism to rotate together, the walking mechanism is rotated to the direction of the second straight track section, and the walking mechanism is started again to walk along the second straight track section. ​

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