Rolling formwork device and construction technology for dam concrete overflow surface

Abstract

The present invention discloses a rolling formwork device for the overflow surface of a dam concrete, wherein overflow surface steel bars are arranged in the overflow surface; the lower layer of the construction position is the first-phase concrete that has been constructed; it includes a track mechanism, and the curvature of the bearing surface of the track mechanism is the same as and flush with the overflow surface; the track mechanism carries a climbing mechanism upward through a rolling formwork mechanism; the rolling formwork mechanism includes a crawler formwork structure, a rubber belt and a counterweight structure; the rubber belt is used as a rolling formwork as a top formwork when pouring the overflow surface concrete; the crawler formwork structure includes a crawler formwork composed of a plurality of formwork pieces, and the crawler formwork is used to match overflow surfaces with different curvatures. The present invention also discloses a corresponding construction process. The present invention adopts the same set of devices to meet the needs of pouring and constructing overflow surface concrete with a variety of different curvatures, without the need to design different formworks for specific projects, and when the curvature of the same overflow surface changes, there is no need to replace the formwork, which greatly facilitates the construction of overflow surface concrete.

Description

Technical Field

[0001] The invention relates to the field of water conservancy project construction, in particular to a rolling template device and a construction process for pouring a dam concrete overflow surface. Background Art

[0002] At present, the construction of the dam overflow surface concrete adopts the sliding formwork or flip formwork construction process. During the lifting process of the sliding formwork, the formwork slides upward along the surface of the concrete. Due to the friction of the formwork and the bonding force of the concrete, the formwork will pull the surface of the concrete, causing them to be subjected to an upward shear force, thus causing horizontal cracks and vertical pull marks on the concrete surface.

[0003] The timing of lifting the formwork in slipform construction is very critical. If it is lifted too early, the concrete strength will be insufficient and the surface of the concrete will be easily damaged; if it is lifted too late, the formwork will not slide, which will cause the slipform construction to fail.

[0004] The flip formwork developed from the slip formwork has changed the way the formwork is lifted and solved the problem of damaging the concrete surface, but the flip formwork construction process is more complicated than the slip formwork, the lifting speed is slower than the slip formwork, and the construction efficiency is lower than the slip formwork.

[0005] When the arc segment of the concrete overflow surface is an irregular function curve, the fixed plane template cannot guarantee the accuracy of the concrete overflow surface contour line, and the fixed curved surface template cannot be pulled and slid.

[0006] In the Chinese patent "A concrete curved surface drawing device capable of ensuring continuous casting construction" with announcement number CN 216042581 U, the direction of the traction force and the sliding direction of the arc template are inconsistent, and continuous sliding construction cannot be achieved.

[0007] The template described in the Chinese patent "Crawler grooved template for rockfill dam concrete panel and slope concrete construction process" with announcement number CN 112502100 B avoids sliding friction between the concrete surface and the template surface. Since the crawler template of the patent is a fixed plane template, it cannot automatically adjust with the concrete overflow surface curve and cannot ensure the accuracy of the concrete overflow surface contour line. It is not suitable for use in concrete working conditions such as when the concrete overflow surface is a curved surface. Summary of the invention

[0008] The object of the present invention is to provide a rolling formwork device for a dam concrete overflow surface, which can adapt to overflow surfaces with various curvatures by using the same set of devices and is applicable to sections of the same overflow surface with different curvatures.

[0009] To achieve the above object, the present invention provides a rolling template device for the overflow surface of a dam concrete, wherein overflow surface reinforcement is arranged in the overflow surface; the position where the concrete is to be poured on the overflow surface to be constructed is called the construction position, and the lower layer of the construction position is the first-phase concrete that has been constructed;

[0010] It includes a track mechanism, wherein the curvature of the bearing surface of the track mechanism is the same as and flush with the overflow surface;

[0011] The track mechanism carries a climbing mechanism upward through a rolling template mechanism;

[0012] The climbing mechanism is used to drive the rolling template mechanism to climb upward along the track mechanism;

[0013] The rolling formwork mechanism includes a crawler formwork structure, a rubber belt and a counterweight structure; the crawler formwork structure and the rubber belt are wound around the climbing mechanism, and the rubber belt is used as a rolling formwork and as a top formwork when pouring concrete on the overflow surface;

[0014] The crawler template structure includes a crawler template composed of a plurality of template sheets, and the crawler template is used to match overflow surfaces with different curvatures.

[0015] The track mechanism comprises a track, the track extends in the up-down direction of the overflow surface, the cross section of the track is a groove shape with an opening upward, the bottom plate of the track is connected with a pre-embedded threaded anchor rod, the pre-embedded threaded anchor rod extends downward into the first-phase concrete; the top end of the pre-embedded threaded anchor rod is higher than the bottom plate of the track and is located in the groove surrounded by the track, the top of the pre-embedded threaded anchor rod is threadedly connected with a nut, the nut is tightly pressed on the bottom plate of the track and is used to locate the vertical position of the pre-embedded threaded anchor rod;

[0016] The track and its embedded threaded anchor rod are provided with two sets symmetrically on the left and right, and the top surface of the track serves as the bearing surface of the track mechanism.

[0017] The climbing mechanism comprises a frame, with the climbing direction as the forward direction, the front end of the frame is rotatably connected to a front axle, and the rear end of the frame is rotatably connected to a rear axle; the front axle and the rear axle both extend horizontally in a left-right direction perpendicular to the track;

[0018] A reduction winch is connected to the left or right end of the frame, and the output shaft of the reduction winch is connected to the front shaft or the rear shaft through a coupling;

[0019] The front axle or rear axle connected to the reduction winch is the driving axle, and the rear axle or front axle is the driven axle;

[0020] A plurality of driving sprockets are installed on the driving shaft at intervals on the left and right, and a plurality of driven sprockets are installed on the driven shaft at intervals on the left and right. The driving sprockets correspond to the driven sprockets one by one, and a transmission chain is wound between the corresponding driving sprockets and the driven sprockets.

[0021] The driving sprocket, the driven sprocket and the transmission chain form a transmission device, and the transmission device is provided with multiple sets at intervals along the left and right directions;

[0022] A fixed pulley anchor rod is pre-buried in the first-phase concrete below the overflow surface of the dam to be constructed, and a fixed pulley is installed on the top of the fixed pulley anchor rod; two fixed pulleys are provided at the left end and the right end of the driving shaft;

[0023] A lifting wire rope is wound on the drum of the reduction winch, and a lifting ring is installed at the other end of the driving shaft away from the winch. A traction bearing is installed outside the lifting ring. The lifting wire rope passes forward around two fixed pulleys and is connected to the outer ring of the traction bearing.

[0024] The template pieces of the crawler formwork correspond one to one with the links of the transmission chain, with the outer direction of the closed curve surrounded by the transmission chain as the outward direction. The template pieces of the crawler formwork are connected to the outside of the links of the transmission chain and rotate with the links; the outer cover of the crawler formwork is provided with the rubber belt; the left and right widths of the rubber belt are the maximum single-width construction width of the rolling formwork.

[0025] The frame is a telescopic connecting beam connected between the front axle and the rear axle; two sets of telescopic connecting beams are symmetrically arranged on the left and right;

[0026] The telescopic connecting beam comprises a front connecting rod connected to the front axle and a rear sleeve connected to the rear axle, the front end of the rear sleeve is open, and the rear part of the front connecting rod extends backward into the rear sleeve; a front spring support is provided on the radial protrusion of the front connecting rod in front of the rear sleeve, and a rear spring support is provided on the radial protrusion of the front part of the rear sleeve, and a limiting rod is inserted between the front spring support and the rear spring support, and the limiting rod is fixedly connected to the front spring support and slides through the rear spring support; a return spring is sleeved on the limiting rod between the front spring support and the rear spring support, and the return spring is press-fitted with the front spring support and the rear spring support; the limiting rod and the return spring form a set of return devices, and more than two sets of return devices are evenly arranged along the circumferential direction;

[0027] The tensioning mechanism comprises a first tensioning rod fixedly connected to the telescopic connecting beam at the end of the driving shaft and a second tensioning rod rotatably connected to the end of the driving shaft, the first tensioning rod and the second tensioning rod both extend in the radial direction of the driving shaft and both extend out of the crawler template; the end of the second tensioning rod is connected to the end of the first tensioning rod through a distance adjustment device; the end of the second tensioning rod is connected to a supporting wheel, which extends to the bottom of the rubber belt and supports the rubber belt upward; the end of the first tensioning rod is connected to a pressing wheel, which extends to the top of the rubber belt and presses the rubber belt downward;

[0028] The distance adjustment device comprises a first hinge seat hinged on the first tensioning rod and a second hinge seat hinged on the second tensioning rod, the first hinge seat is a cylindrical structure and an end cap is provided at one end thereof facing the second hinge seat, the second hinge seat is fixedly connected with an adjustment rod, the adjustment rod slides through the end cap and extends into the first hinge seat, an adjustment spring is sleeved on the adjustment rod between the end cap and the second hinge seat, and the adjustment spring is press-fitted with the end cap and the second hinge seat;

[0029] The tensioning mechanism is symmetrically provided with two sets on the telescopic connecting beam and is used to keep the rubber belt in a tensioned state;

[0030] The counterweight structure includes a plurality of counterweight beams and a front axle sleeve connected to the front axle and a rear axle sleeve connected to the rear axle, and each counterweight beam extends in the left-right direction; a steel hinge is connected between the front axle sleeve and the rear axle sleeve, and the steel hinge passes through the plurality of counterweight beams; the front axle sleeve, the rear axle sleeve and the steel hinge constitute a group of suspension devices, and the suspension devices are provided with multiple sets at intervals on the left and right along the length direction of the counterweight beam; each counterweight beam is downwardly connected to a plurality of clamping wheels, and the clamping wheels are provided in multiple rows corresponding to the transmission chains, and the number of clamping wheels in each row corresponds to the counterweight beam; the clamping wheels press downward on the transmission chains of the corresponding transmission devices; the counterweight beam is a vertical rectangular parallelepiped structure; pressure sensors are respectively provided on the clamping wheels at two locations;

[0031] Lifting rings for lifting are respectively provided at both ends of the driven shaft.

[0032] With a vertical height of 30 cm as one layer, the time required for pouring one layer of overflow surface concrete is t, the time required for pouring overflow surface concrete from the time the concrete enters the warehouse to the time the concrete reaches the demoulding strength is T, the maximum inclination angle of the overflow surface is a, and the distance between the driving shaft and the driven shaft is L=30T / t×sina. The concrete pouring strength matches the allowable demoulding strength, reducing construction intervals and ensuring continuous concrete pouring.

[0033] The present invention also discloses a construction process using the above-mentioned dam concrete overflow surface rolling template device, which is carried out according to the following steps:

[0034] The first step is preliminary preparation;

[0035] Pre-embed the fixed pulley anchor rod and the embedded threaded anchor rod at the track in the first-phase concrete; install the overflow surface reinforcement and the side formwork, with the embedded threaded anchor rod located outside the side formwork; install the left and right tracks on the embedded threaded anchor rods on the left and right sides respectively; the fixed pulley anchor rod is located in the front and upper part of the two tracks and is provided with two corresponding to the two tracks;

[0036] A fixed pulley is respectively installed on the two fixed pulley anchor rods through a wheel frame;

[0037] The second step is the pouring of the first section of concrete;

[0038] Pour the first section of concrete at the bottom of the construction location;

[0039] The third step is assembly and debugging;

[0040] After the rolling formwork mechanism and the climbing mechanism are assembled, they are placed on the track 5 at the position to be poured on the overflow surface 1 of the dam. The rolling formwork covers the first-stage concrete and is ahead of the first section of concrete. The amount of advance is based on the vertical height difference of 30 cm between the front end of the rolling formwork and the first section of concrete. The climbing mechanism is connected and debugged;

[0041] The fourth step is to pour the overflow surface concrete of the initial section;

[0042] The length of the overflow surface concrete of the initial section along the overflow surface is the arc length of the overflow surface between the driving shaft and the driven shaft, and the overflow surface of the initial section is located at the lowest part of the overflow surface;

[0043] The overflow surface above the overflow surface of the starting section is called the overflow surface of the main section;

[0044] The front end of the crawler formwork structure and the first-stage concrete 2 thereunder form a pouring opening; the pouring action is performed;

[0045] The pouring action is: pouring concrete from the pouring opening to the position to be poured below the crawler formwork structure. Specifically, the staff uses the chute to pour the concrete with adjusted slump from top to bottom into the pouring opening. When the vertical height of the poured concrete reaches 30 cm, the concrete is vibrated using an inserted vibrator;

[0046] Each pouring action completes the pouring of one layer of concrete;

[0047] After the pouring action is completed, the climbing action is performed manually;

[0048] The climbing action is: start the deceleration winch 9, which drives its drum and the driving shaft 10 to rotate simultaneously; when the drum rotates, the lifting wire rope 17 is wound on the drum, so that the drum and the traction bearing 19 are subjected to the traction force from the fixed pulley 16, so that the concrete overflow surface rolling template device is advanced forward and upward along the track 5; at the same time, the driving shaft 10 drives the transmission chain 14 and the driven sprocket 13 to rotate through the driving sprocket 12, and the transmission chain 14 drives the crawler template to rotate; after the concrete overflow surface rolling template device moves forward and upward along the track 5 to a vertical height of 30 cm, the deceleration winch 9 is turned off to complete the climbing action;

[0049] After the climbing action is completed, the pouring action is returned; the pouring action and the climbing action are performed alternately until the concrete pouring of the overflow surface of the starting section is completed;

[0050] The fifth step is to pour the overflow surface concrete of the main section;

[0051] When the first layer of concrete on the overflow surface of the starting section reaches the designed demolding strength, the climbing action is performed manually or automatically, and the climbing action and pouring action are performed alternately until the concrete overflow surface rolling formwork device moves forward and upward to the top of the dam overflow surface, completing the pouring of the overflow surface concrete.

[0052] In the third step, a release agent is applied to the outer surface of the rubber belt.

[0053] When the overflow surface width is larger than the maximum width of a single-section rolling formwork, it is divided into multiple sections for construction, and the split side formwork is installed on the side of the dam slope where the pouring position is to be located; each section of construction is carried out according to the first to fifth steps.

[0054] The present invention has the following advantages:

[0055] The present invention adopts a rolling formwork device to cast the concrete overflow surface. The rolling formwork construction technology retains all the advantages of the slipform construction, improves the relative movement relationship between the formwork and the concrete during the formwork lifting process, avoids the disadvantage that the concrete surface is easily cracked during the slipform construction, and can make the concrete surface dense, flat and smooth, which is a great improvement for the long slope concrete casting construction.

[0056] The crawler-type formwork of the present invention can match overflow surfaces with various curvatures, and the same set of devices can be used to meet the needs of concrete pouring construction of overflow surfaces with various curvatures. There is no need to design different formworks for specific projects (with specific overflow surface curvatures), and there is no need to replace the formwork when the curvature of the same overflow surface changes (with multiple sections with different curvatures). The present invention is simple and convenient to use, has strong versatility, and greatly facilitates the construction of overflow surface concrete.

[0057] The track mechanism is convenient to install and use, and is convenient for carrying the rolling formwork mechanism so that the rubber belt is used as the top formwork when pouring overflow surface concrete.

[0058] The climbing mechanism has a simple structure and uses a winch to

[0059] Pulling on both sides at the same time ensures balanced traction and prevents the vehicle from running off the track.

[0060] The other end of the lifting wire rope is connected to the outer ring of the bearing instead of the lifting ring because it is necessary to ensure that the lifting wire is only wound around the drum and not around the driving shaft at the lifting ring. The counterweight beam is a vertical rectangular structure to solve the deflection problem.

[0061] The telescopic connecting beam, the tensioning mechanism and the counterweight structure cooperate with each other. The three are indispensable and must function simultaneously. If the telescopic connecting beam is used alone without the coordination of the tensioning mechanism and the counterweight structure, when the curvature of the overflow surface changes, the rubber formwork will be torn or loosened, and cannot be used as a top formwork for concrete pouring. Without the telescopic connecting beam, the present invention cannot adapt to the change of the curvature of the overflow surface.

[0062] In summary, in order for the present invention to be able to automatically and adaptively adjust the state of the rubber formwork and play the role of a top formwork when the curvature of the overflow surface changes, the telescopic connecting beam, the tensioning mechanism and the counterweight structure are indispensable, and the three cannot be separated for technical considerations; the organic combination of the three to adjust the state of the rubber formwork and play the role of a top formwork is an original creation of the present invention, and there is no similar prior art in the field.

[0063] The tensioning mechanism keeps the rubber belt in a tensioned state at all times. When the rubber belt deforms to adapt to the overflow surface curve (the rubber belt always fits the overflow surface curve under the action of gravity, and always maintains a tensioned state under the action of the tensioning mechanism), the spacing between the driving shaft and the driven shaft will be forced to change. Similarly, under the action of the counterweight, the counterweight structure presses the transmission chain downward, so that the transmission chain always fits the crawler template, and the crawler template is always pressed downward and fits the rubber belt, and together with the tensioning mechanism, the axis spacing is forced to change adaptively (to adapt to the change in the curvature of the overflow surface). That is, the telescopic connecting beam, the tensioning mechanism, and the counterweight structure cooperate with each other, so that the present invention can adjust the axis spacing between the driving shaft and the driven shaft to adapt to the change in the curvature of the overflow surface, and in this process, the transmission chain, crawler template, and rubber belt can synchronously adapt to the change in the curvature of the overflow surface to match and adjust their own bottom shape.

[0064] The present invention allows the axial spacing between the driving shaft and the driven shaft to adaptively change with the overflow surface curve, while keeping the rubber belt in a tensioned state and obtaining a downward tightening pressure from the counterweight structure, so that the bottom shape of the rubber belt adapts to the curvature of the overflow surface and can continue to serve as a top mold for pouring concrete on the overflow surface when the curvature of the overflow surface changes.

[0065] The process of the present invention is simple and convenient. It is not necessary to make different top templates for overflow surfaces with different curvatures. In the process of pouring from the back to the front along the overflow surface of the dam, it is not necessary to use different top templates due to the change of the curvature of the overflow surface, which greatly facilitates the construction of the overflow surface. It is not necessary to make different top templates, so that the pouring efficiency of the overflow surface concrete is greatly improved. The pressure sensor is set to provide a basis for automatic climbing control. Combined with L=30T / t×sin(a), L is the distance between the driving shaft and the driven shaft, which can avoid the loss of concrete strength in the later stage caused by climbing too fast, and also avoid the problem of low construction efficiency caused by climbing too slowly.

[0066] The purpose of applying release agent to the rubber belt is to facilitate the rubber belt of the rolling formwork to be smoothly demolded from the overflow surface concrete when moving forward and upward, and not to stick to the concrete during separation. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Figure 1 It is a top view structural diagram of the concrete overflow surface rolling formwork device. Figure 1 The tensioning mechanism and rubber belt are omitted;

[0068] Figure 2 It is a side view structural schematic diagram of the concrete overflow surface rolling template device when working along the overflow surface;

[0069] Figure 3 yes Figure 1 CC view and Figure 3 Only the structure below the counterweight beam is expressed;

[0070] Figure 4 yes Figure 1 Right view of Figure 4 The lifting rings, traction bearings, fixed pulleys and lifting wire ropes are omitted.

[0071] Figure 5 This is an enlarged view of the structure of the front connecting rod and the rear sleeve joint;

[0072] Figure 6 yes Figure 1 BB view, Figure 6 The tensioning mechanism other than the supporting wheel and the pressure wheel is omitted.

[0073] Figure 7 yes Figure 3 Enlarged view of point A in the middle. DETAILED DESCRIPTION

[0074] like Figures 1 to 7 As shown, the present invention provides a rolling formwork device for a dam concrete overflow surface, wherein overflow surface steel bars are arranged inside the overflow surface 1; the position where concrete is to be poured on the overflow surface 1 to be constructed is called the construction position, and the lower layer of the construction position is the first-phase concrete 2 that has been constructed; the steel bars of the overflow surface 1 are conventional technology, which is not shown in the figure.

[0075] It includes a track mechanism, the curvature of the bearing surface of the track mechanism is the same as and flush with the overflow surface 1;

[0076] The track mechanism carries a climbing mechanism upward through a rolling template mechanism;

[0077] The climbing mechanism is used to drive the rolling template mechanism to climb upward along the track mechanism;

[0078] The rolling formwork mechanism includes a crawler formwork structure, a rubber belt 3 and a counterweight structure; the crawler formwork structure and the rubber belt 3 are wound around the climbing mechanism, and the rubber belt 3 is used as a rolling formwork as a top formwork when pouring concrete on the overflow surface 1;

[0079] The crawler template structure includes a crawler template composed of a plurality of template sheets 4, and the crawler template is used to match overflow surfaces 1 with different curvatures. When the overflow surface 1 is a plane, the curvature is 0.

[0080] The crawler-type template of the present invention can match overflow surfaces 1 with various curvatures, and the same set of devices can be used to meet the needs of concrete pouring construction of overflow surfaces 1 with various curvatures. There is no need to design different templates for specific projects (with specific overflow surface 1 curvatures), and there is no need to replace the template when the curvature of the overflow surface 1 changes. The invention is simple and convenient to use, has strong versatility, and greatly facilitates the concrete construction of the overflow surface 1.

[0081] The track mechanism includes a track 5, which extends in the up-down direction of the overflow surface 1. The cross section of the track 5 is a groove-shaped track with an opening facing upward (the track 5 is made of a channel steel with an opening facing upward). The bottom plate of the track 5 is connected with a pre-embedded threaded anchor rod 6, which extends downward into the first-phase concrete 2 (i.e., the lower layer of concrete of the overflow surface that has been constructed, which is usually plain concrete without steel bars, while the concrete of the overflow surface 1 has steel bars); the top of the pre-embedded threaded anchor rod 6 is higher than the bottom plate of the track 5 and is located in the groove surrounded by the track 5. The top of the pre-embedded threaded anchor rod 6 is threadedly connected with a nut 7, which is tightly pressed on the bottom plate of the track 5 and is used to locate the vertical position of the pre-embedded threaded anchor rod 6;

[0082] The track 5 and its embedded threaded anchor rod 6 are provided in two sets symmetrically on the left and right, and the top surface of the track 5 serves as the bearing surface of the track mechanism.

[0083] Figure 3 and Figure 7 The length of the embedded threaded anchor rod 6 is not shown in proportion. The embedded threaded anchor rod 6 actually extends downward from the overflow surface concrete 8 for a long time, that is, it extends into the first phase concrete 2 for a long time. The track mechanism is convenient for installation and use, and is convenient for carrying the rolling template mechanism to make the rubber belt 3 as the top template when pouring the overflow surface concrete 8.

[0084] The climbing mechanism includes a frame 20, with the climbing direction being the forward direction, the front end of the frame 20 is rotatably connected to a front axle, and the rear end of the frame 20 is rotatably connected to a rear axle; the front axle and the rear axle both extend horizontally in a left-right direction perpendicular to the track 5;

[0085] The left or right end of the frame 20 is connected to a reduction winch 9, and the output shaft of the reduction winch 9 is connected to the front axle or the rear axle through a coupling; the reduction winch 9 can be connected to the frame 20 through a mounting frame, and mounting the winch on the frame 20 is a conventional technology. Figure 1For simplifying the drawings, the structure indicated by reference numeral 9 represents both the reduction winch and the drum of the reduction winch.

[0086] The front axle or rear axle connected to the reduction winch 9 is a driving axle 10, and correspondingly, the rear axle or front axle is a driven axle 11;

[0087] A plurality of driving sprockets 12 are installed on the driving shaft 10 at intervals on the left and right, and a plurality of driven sprockets 13 are installed on the driven shaft 11 at intervals on the left and right. The driving sprockets 12 and the driven sprockets 13 correspond to each other one by one, and a transmission chain 14 is wound between the corresponding driving sprockets 12 and the driven sprockets 13.

[0088] The driving sprocket 12, the driven sprocket 13 and the transmission chain 14 form a transmission device, and the transmission device is provided with multiple sets at intervals along the left and right directions;

[0089] A fixed pulley anchor rod 15 is pre-buried in the first-phase concrete 2 below the overflow surface 1 of the dam to be constructed, and a fixed pulley 16 is installed on the top of the fixed pulley anchor rod 15; two fixed pulleys 16 are provided corresponding to the left end and the right end of the driving shaft 10;

[0090] A lifting wire rope 17 is wound around the drum of the reduction winch 9, and a lifting ring 18 is installed at the other end of the driving shaft 10 away from the winch. A traction bearing 19 is installed outside the lifting ring 18. The lifting wire rope 17 passes forward around the two fixed pulleys 16 and is connected to the outer ring of the traction bearing 19.

[0091] The climbing mechanism has a simple structure, and uses a winch to pull on both sides at the same time, so the traction force is balanced and not easy to deviate. The other end of the lifting wire rope 17 is connected to the outer ring of the bearing instead of the lifting ring 18, because it is necessary to ensure that the lifting wire is only wound on the drum, and will not be wound on the driving shaft 10 at the lifting ring 18.

[0092] The template sheet 4 of the crawler formwork corresponds one-to-one to the chain links of the transmission chain 14, with the outer direction of the closed curve surrounded by the transmission chain 14 as the outward direction, and the template sheet 4 of the crawler formwork is connected to the outside of the chain links of the transmission chain 14 and rotates with the chain links; the crawler formwork cover is provided with the rubber belt 3; the left and right widths of the rubber belt 3 are the maximum width of a single-width construction of the rolling formwork (preferably 5-10 meters, including both end values); in this embodiment, the template sheet 4 (chain link length) of the crawler formwork is about 10 centimeters wide.

[0093] The frame 20 is a telescopic connecting beam connected between the front axle and the rear axle; two sets of telescopic connecting beams are symmetrically arranged on the left and right;

[0094] The telescopic connecting beam comprises a front connecting rod 21 connected to the front axle and a rear sleeve 22 connected to the rear axle, the front end of the rear sleeve 22 is open, and the rear part of the front connecting rod 21 extends backward into the rear sleeve 22; a front spring support 23 is radially protruded on the front connecting rod 21 in front of the rear sleeve 22, and a rear spring support 24 is radially protruded on the front part of the rear sleeve 22, and a limiting rod 25 is inserted between the front spring support 23 and the rear spring support 24, and the limiting rod 25 is fixedly connected to the front spring support 23 and slides through the rear spring support 24; a return spring 26 is sleeved on the limiting rod 25 between the front spring support 23 and the rear spring support 24, and the return spring 26 is press-fitted with the front spring support 23 and the rear spring support 24; the limiting rod 25 and the return spring 26 form a set of return devices, and the return devices are evenly provided with more than two sets along the circumferential direction;

[0095] The tensioning mechanism includes a first tensioning rod 27 fixedly connected to the telescopic connecting beam at the end of the driving shaft 10 and a second tensioning rod 28 rotatably connected to the end of the driving shaft 10 (for example, rotatably connected to the end of the driving shaft 10 through a bearing), the first tensioning rod 27 and the second tensioning rod 28 both extend in the radial direction of the driving shaft 10 and both extend out of the crawler template; the end of the second tensioning rod 28 is connected to the end of the first tensioning rod 27 through a distance adjustment device; the end of the second tensioning rod 28 is connected to a supporting wheel 29, which extends to the bottom of the rubber belt 3 and supports the rubber belt 3 upward; the end of the first tensioning rod 27 is connected to a pressing wheel 30, which extends to the top of the rubber belt 3 and presses the rubber belt 3 downward;

[0096] The distance adjustment device includes a first hinge seat 31 hinged on the first tensioning rod 27 and a second hinge seat 32 hinged on the second tensioning rod 28. The first hinge seat 31 is a cylindrical structure and an end cap 35 is provided at one end thereof facing the second hinge seat 32. An adjustment rod 33 is fixedly connected to the second hinge seat 32. The adjustment rod 33 slides through the end cap 35 and extends into the first hinge seat 31. An adjustment spring 34 is sleeved on the adjustment rod 33 between the end cap 35 and the second hinge seat 32. The adjustment spring 34 is press-fitted with the end cap 35 and the second hinge seat 32.

[0097] The tensioning mechanism is symmetrically provided with two sets on the telescopic connecting beam and is used to keep the rubber belt 3 in a tensioned state;

[0098] The counterweight structure includes a plurality of counterweight beams 36, a front axle sleeve 37 connected to the front axle, and a rear axle sleeve 38 connected to the rear axle. Each counterweight beam 36 extends in the left-right direction. A steel hinge 39 is connected between the front axle sleeve 37 and the rear axle sleeve 38, and the steel hinge 39 passes through the plurality of counterweight beams 36. The front axle sleeve 37, the rear axle sleeve 38 and the steel hinge 39 form a set of suspension devices, and the suspension devices are provided with multiple sets at intervals along the length direction of the counterweight beam 36. Each counterweight beam 36 is connected downwardly to a plurality of clamping wheels 40, and the clamping wheels 40 are provided in multiple rows corresponding to the transmission chain one by one, and the number of clamping wheels 40 in each row corresponds to the counterweight beam 36 one by one. The clamping wheels 40 press downwardly on the transmission chain 14 of the corresponding transmission device. The counterweight beam 36 is a vertical rectangular parallelepiped structure to solve the deflection problem. Pressure sensors 42 are provided on the clamping wheels 40 at two locations, respectively.

[0099] The telescopic connecting beam, the tensioning mechanism and the counterweight structure cooperate with each other, and the three are indispensable and must work together. If the telescopic connecting beam is used alone without the tensioning mechanism and the counterweight structure, when the curvature of the overflow surface 1 changes, the rubber formwork will be torn or loosened, and cannot be used as a top form for concrete pouring. Without the telescopic connecting beam, the present invention cannot adapt to the change of the curvature of the overflow surface 1.

[0100] In summary, in order for the present invention to be able to automatically and adaptively adjust the state of the rubber formwork and play the role of a top formwork when the curvature of the overflow surface 1 changes, the telescopic connecting beam, the tensioning mechanism and the counterweight structure are indispensable, and the three cannot be separated for technical consideration; the organic combination of the three to adjust the state of the rubber formwork and play the role of a top formwork is an original creation of the present invention, and there is no similar prior art in the field.

[0101] The tensioning mechanism makes the rubber belt 3 always in a tensioned state. When the rubber belt 3 deforms to adapt to the overflow surface 1 curve (the rubber belt 3 always fits the overflow surface 1 curve under the action of gravity, and always maintains a tensioned state under the action of the tensioning mechanism), it will force the distance between the driving shaft 10 and the driven shaft 11 to change; similarly, under the action of the counterweight, the counterweight structure presses the transmission chain 14 downward, so that the transmission chain 14 always fits the crawler template, and then the crawler template always presses down and fits the rubber belt 3, and together with the tensioning mechanism, forces the axis spacing to change adaptively (to adapt to the change of the curvature of the overflow surface 1). That is, the telescopic connecting beam, the tensioning mechanism and the counterweight structure cooperate with each other, so that the present invention can adjust the axis spacing between the driving shaft 10 and the driven shaft 11 to adapt to the change of the curvature of the overflow surface 1, and in this process, the transmission chain 14, the crawler template and the rubber belt 3 synchronously adapt to the change of the curvature of the overflow surface 1 to match and adjust their own bottom shape.

[0102] The present invention allows the axial spacing between the driving shaft 10 and the driven shaft 11 to adaptively change with the curve of the overflow surface 1, while keeping the rubber belt 3 in a tensioned state and obtaining the downward tightening pressure of the counterweight structure, so that the bottom shape of the rubber belt 3 adapts to the curvature of the overflow surface 1 and can continue to serve as the top mold for pouring the overflow surface concrete 8 when the curvature of the overflow surface 1 changes.

[0103] Both ends of the driven shaft 11 are provided with lifting rings 18 for lifting. With a vertical height of 30 cm as one layer (vertical height refers to the direction perpendicular to the horizontal plane, not the direction perpendicular to the overflow surface), the time required for pouring one layer of concrete on the overflow surface is t, the time required for pouring concrete on the overflow surface from the time the concrete enters the warehouse to the time the concrete reaches the demoulding strength is T, the maximum inclination angle of the overflow surface is a, and the distance between the driving shaft and the driven shaft is L=30T / t×sina(a). The concrete pouring strength matches the allowable demoulding strength, reducing construction intervals and ensuring continuous concrete pouring.

[0104] The present invention also discloses a construction process using the above-mentioned dam concrete overflow surface rolling template device, which is carried out according to the following steps:

[0105] The first step is preliminary preparation;

[0106] In the first-phase concrete 2 (the lower layer of concrete that has been constructed), the fixed pulley anchor rod 15 and the embedded threaded anchor rod 6 at the track 5 are pre-embedded; the overflow surface steel bars are installed, the side formwork 41 is installed, and the embedded threaded anchor rod 6 is located outside the side formwork 41; the left and right tracks 5 are installed on the embedded threaded anchor rods 6 on the left and right sides respectively; the fixed pulley anchor rod 15 is located in front of and above the two tracks 5 and two are provided corresponding to the two tracks 5 one by one;

[0107] A fixed pulley 16 is respectively installed on the two fixed pulley anchor rods 15 through a wheel frame; the wheel frame is conventional technology and is not shown in the figure.

[0108] The second step is the pouring of the first section of concrete.

[0109] Pour the first section of concrete at the lowest section (horizontal section) of the construction location (this is a conventional technique);

[0110] The third step is assembly and debugging;

[0111] After the rolling formwork mechanism and the climbing mechanism are assembled, they are placed on the track 5 at the location where the dam overflow surface 1 is to be poured. The rolling formwork covers the first-stage concrete and is ahead of the first section of concrete. The amount of advance is based on the vertical height difference of 30 cm between the front end of the rolling formwork and the first section of concrete; (The concrete specification is 30 cm per layer.) Connect and debug the climbing mechanism;

[0112] The fourth step is to pour the overflow surface concrete of the initial section;

[0113] The length of the overflow surface concrete of the initial section along the overflow surface is the arc length of the overflow surface between the driving shaft and the driven shaft, and the overflow surface of the initial section is located at the lowest part of the overflow surface (the arc segment);

[0114] The overflow surface above the overflow surface of the starting section is called the overflow surface of the main section;

[0115] The front end of the crawler formwork structure (since it moves upward in an inclined manner, the front end is also the upper end) and the first-stage concrete 2 thereunder form a pouring opening; the pouring action is performed;

[0116] The pouring action is: pouring concrete from the pouring opening to the position to be poured below the crawler formwork structure. Specifically, the staff uses the chute to pour the concrete with adjusted slump from top to bottom into the pouring opening. When the vertical height of the poured concrete reaches 30 cm (the layer height specified in the specification), the concrete is vibrated using an inserted vibrator;

[0117] Each pouring action completes the pouring of one layer of concrete (vertical height 30 cm);

[0118] After the pouring action is completed, the climbing action is performed manually;

[0119] The climbing action is: start the deceleration winch 9, which drives its drum and the driving shaft 10 to rotate simultaneously; when the drum rotates, the lifting wire rope 17 is wound on the drum, so that the drum and the traction bearing 19 are subjected to the traction force from the fixed pulley 16, so that the concrete overflow surface rolling template device is advanced forward and upward along the track 5; at the same time, the driving shaft 10 drives the transmission chain 14 and the driven sprocket 13 to rotate through the driving sprocket 12, and the transmission chain 14 drives the crawler template to rotate; after the concrete overflow surface rolling template device moves forward and upward along the track 5 to a vertical height of 30 cm, the deceleration winch 9 is turned off to complete the climbing action;

[0120] After the climbing action is completed, the pouring action is returned; the pouring action and the climbing action are performed alternately until the concrete pouring of the overflow surface of the starting section is completed;

[0121] The fifth step is to pour the overflow surface concrete of the main section;

[0122] When the first layer of concrete on the overflow surface of the starting section reaches the designed demolding strength, manual (or automatic) control is used to perform a climbing action, alternating between the climbing action and the pouring action, until the concrete overflow surface rolling formwork device moves forward and upward to the top of the dam overflow surface 1, completing the pouring of the overflow surface concrete 8.

[0123] In the fifth step, the demoulding strength of the overflow surface concrete can be monitored by the pressure sensor 42. Two pressure sensors 42 can be set on the two clamping wheels 40, and the pressure sensors 42 are connected to the electronic control device (such as a single chip microcomputer or industrial control computer with a display screen, preferably using the climbing control system in the publication number CN115354849A), and the pressure sensor 42 is used to automatically monitor whether the overflow surface concrete 8 reaches the demoulding strength, thereby providing a basis for automatic control. Any conventional improvements and any additional improvements made on the basis of the present invention fall within the protection scope of the present invention.

[0124] In the third step, a release agent is applied to the outer surface of the rubber belt 3. The purpose of applying the release agent to the rubber belt is to facilitate the rubber belt 3 of the rolling template to be smoothly demolded with the overflow surface concrete 8 when moving forward and upward, and not to adhere to the concrete when separating.

[0125] When the width of the overflow surface 1 is greater than the maximum width of the single-section construction of the rolling template, it is divided into multiple sections for construction, and the split side template 41 is installed on one side of the dam slope where the pouring position is to be located; each section of construction is performed according to the first to fifth steps.

[0126] The above embodiments are only used to illustrate rather than limit the technical solutions of the present invention. Although the present invention is described in detail with reference to the above embodiments, those skilled in the art should understand that the present invention can still be modified or replaced by equivalents. Any modification or partial replacement that does not depart from the spirit and scope of the present invention should be included in the scope of the claims of the present invention.

Claims

1. A rolling formwork device for the overflow surface of a dam concrete, wherein overflow surface reinforcement is arranged in the overflow surface; the position where the concrete is to be poured on the overflow surface to be constructed is called the construction position, and the lower layer of the construction position is the first-phase concrete that has been constructed; the characteristics are: It includes a track mechanism, wherein the curvature of the bearing surface of the track mechanism is the same as and flush with the overflow surface; The track mechanism carries a climbing mechanism upward through a rolling template mechanism; The climbing mechanism is used to drive the rolling template mechanism to climb upward along the track mechanism; The rolling formwork mechanism includes a crawler formwork structure, a rubber belt and a counterweight structure; the crawler formwork structure and the rubber belt are wound around the climbing mechanism, and the rubber belt is used as a rolling formwork and as a top formwork when pouring concrete on the overflow surface; The crawler template structure includes a crawler template composed of a plurality of template sheets, and the crawler template is used to match overflow surfaces with different curvatures; The track mechanism comprises a track, the track extends in the up-down direction of the overflow surface, the cross section of the track is a groove shape with an opening upward, the bottom plate of the track is connected with a pre-embedded threaded anchor rod, the pre-embedded threaded anchor rod extends downward into the first-phase concrete; the top end of the pre-embedded threaded anchor rod is higher than the bottom plate of the track and is located in the groove surrounded by the track, the top of the pre-embedded threaded anchor rod is threadedly connected with a nut, the nut is tightly pressed on the bottom plate of the track and is used to locate the vertical position of the pre-embedded threaded anchor rod; The track and its embedded threaded anchor rods are provided with two sets symmetrically on the left and right, and the top surface of the track serves as the bearing surface of the track mechanism; The climbing mechanism comprises a frame, with the climbing direction as the forward direction, the front end of the frame is rotatably connected to a front axle, and the rear end of the frame is rotatably connected to a rear axle; the front axle and the rear axle both extend horizontally in a left-right direction perpendicular to the track; A reduction winch is connected to the left or right end of the frame, and the output shaft of the reduction winch is connected to the front shaft or the rear shaft through a coupling; The front axle or rear axle connected to the reduction winch is the driving axle, and the rear axle or front axle is the driven axle; A plurality of driving sprockets are installed on the driving shaft at intervals on the left and right, and a plurality of driven sprockets are installed on the driven shaft at intervals on the left and right. The driving sprockets correspond to the driven sprockets one by one, and a transmission chain is wound between the corresponding driving sprockets and the driven sprockets. The driving sprocket, the driven sprocket and the transmission chain form a transmission device, and the transmission device is provided with multiple sets at intervals along the left and right directions; A fixed pulley anchor rod is pre-buried in the first-phase concrete below the overflow surface of the dam to be constructed, and a fixed pulley is installed on the top of the fixed pulley anchor rod; two fixed pulleys are provided at the left end and the right end of the driving shaft; A lifting wire rope is wound on the drum of the speed reduction winch, and a lifting ring is installed at the other end of the driving shaft away from the winch. A traction bearing is installed outside the lifting ring. The lifting wire rope passes forward around two fixed pulleys and is connected to the outer ring of the traction bearing. The template pieces of the crawler template correspond to the links of the transmission chain one by one, with the outer direction of the closed curve surrounded by the transmission chain as the outward direction, and the template pieces of the crawler template are connected to the outside of the links of the transmission chain and rotate with the links; the outer cover of the crawler template is provided with the rubber belt; the left and right widths of the rubber belt are the maximum width of a single construction of the rolling template; The frame is a telescopic connecting beam connected between the front axle and the rear axle; two sets of telescopic connecting beams are symmetrically arranged on the left and right; The telescopic connecting beam comprises a front connecting rod connected to the front axle and a rear sleeve connected to the rear axle, the front end of the rear sleeve is open, and the rear part of the front connecting rod extends backward into the rear sleeve; a front spring support is provided on the radial protrusion of the front connecting rod in front of the rear sleeve, and a rear spring support is provided on the radial protrusion of the front part of the rear sleeve, and a limiting rod is inserted between the front spring support and the rear spring support, and the limiting rod is fixedly connected to the front spring support and slides through the rear spring support; a return spring is sleeved on the limiting rod between the front spring support and the rear spring support, and the return spring is press-fitted with the front spring support and the rear spring support; the limiting rod and the return spring form a set of return devices, and more than two sets of return devices are evenly arranged along the circumferential direction; The tensioning mechanism comprises a first tensioning rod fixedly connected to the telescopic connecting beam at the end of the driving shaft and a second tensioning rod rotatably connected to the end of the driving shaft, the first tensioning rod and the second tensioning rod both extend in the radial direction of the driving shaft and both extend out of the crawler template; the end of the second tensioning rod is connected to the end of the first tensioning rod through a distance adjustment device; the end of the second tensioning rod is connected to a supporting wheel, which extends to the bottom of the rubber belt and supports the rubber belt upward; the end of the first tensioning rod is connected to a pressing wheel, which extends to the top of the rubber belt and presses the rubber belt downward; The distance adjustment device comprises a first hinge seat hinged on the first tensioning rod and a second hinge seat hinged on the second tensioning rod, the first hinge seat is a cylindrical structure and an end cap is provided at one end thereof facing the second hinge seat, the second hinge seat is fixedly connected with an adjustment rod, the adjustment rod slides through the end cap and extends into the first hinge seat, an adjustment spring is sleeved on the adjustment rod between the end cap and the second hinge seat, and the adjustment spring is press-fitted with the end cap and the second hinge seat; The tensioning mechanism is symmetrically provided with two sets on the telescopic connecting beam and is used to keep the rubber belt in a tensioned state; The counterweight structure includes multiple counterweight beams and a front axle sleeve connected to the front axle and a rear axle sleeve connected to the rear axle, and each counterweight beam extends in the left-right direction; a steel hinge is connected between the front axle sleeve and the rear axle sleeve, and the steel hinge passes through the multiple counterweight beams; the front axle sleeve, the rear axle sleeve and the steel hinge constitute a group of suspension devices, and multiple sets of the suspension devices are arranged at intervals on the left and right along the length direction of the counterweight beam; each counterweight beam is downwardly connected to a number of clamping wheels, and the clamping wheels are arranged in multiple rows corresponding to the transmission chains, and the number of clamping wheels in each row corresponds to the counterweight beam; the clamping wheels press downward on the transmission chain of the corresponding transmission device; the counterweight beam is a vertical rectangular structure; pressure sensors are respectively arranged on the two clamping wheels.

2. The concrete overflow surface rolling formwork device according to claim 1, characterized in that: Lifting rings for lifting are respectively provided at both ends of the driven shaft.

3. The concrete overflow surface rolling template device according to claim 2 is characterized in that: Take a layer with a vertical height of 30 cm, and assume that the time required for pouring one layer of overflow surface concrete is t, the time required for pouring overflow surface concrete from the time the concrete enters the warehouse to the time the concrete reaches the demoulding strength is T, the maximum inclination angle of the overflow surface is a, and the distance between the driving shaft and the driven shaft is L=30T / t×sina; the concrete pouring strength is matched with the allowable demoulding strength, which reduces construction intervals and ensures continuous concrete pouring.

4. A construction process using the rolling formwork device for the overflow surface of dam concrete as claimed in claim 3, characterized in that Follow these steps: The first step is preliminary preparation; Pre-embed the fixed pulley anchor rod and the embedded threaded anchor rod at the track in the first-phase concrete; install the overflow surface reinforcement and the side formwork, with the embedded threaded anchor rod located outside the side formwork; install the left and right tracks on the embedded threaded anchor rods on the left and right sides respectively; the fixed pulley anchor rod is located in the front and upper part of the two tracks and is provided with two corresponding to the two tracks; A fixed pulley is respectively installed on the two fixed pulley anchor rods through a wheel frame; The second step is the pouring of the first section of concrete; Pour the first section of concrete at the bottom of the construction location; The third step is assembly and debugging; After the rolling formwork mechanism and the climbing mechanism are assembled, they are placed on the track at the location where the dam overflow surface is to be poured. The rolling formwork covers the first-stage concrete and is ahead of the first section of concrete. The amount of advance is based on the vertical height difference of 30 cm between the front end of the rolling formwork and the first section of concrete. Connect and debug the climbing mechanism; The fourth step is to pour the overflow surface concrete of the initial section; The length of the overflow surface concrete of the initial section along the overflow surface is the arc length of the overflow surface between the driving shaft and the driven shaft, and the overflow surface of the initial section is located at the lowest part of the overflow surface; The overflow surface above the overflow surface of the starting section is called the overflow surface of the main section; The front end of the crawler formwork structure and the first-stage concrete below it form a pouring opening; the pouring action is performed; The pouring action is: pouring concrete from the pouring opening to the position to be poured below the crawler formwork structure. Specifically, the staff uses the chute to pour the concrete with adjusted slump from top to bottom into the pouring opening. When the vertical height of the poured concrete reaches 30 cm, the concrete is vibrated using an inserted vibrator; Each pouring action completes the pouring of one layer of concrete; After the pouring action is completed, the climbing action is performed manually; The climbing action is: start the deceleration winch, which drives its drum and the driving shaft to rotate at the same time; when the drum rotates, the lifting wire rope is wound on the drum, so that the drum and the traction bearing are subjected to the traction force from the fixed pulley, so that the concrete overflow surface rolling template device moves forward and upward along the track; at the same time, the driving shaft drives the transmission chain and the driven sprocket to rotate through the driving sprocket, and the transmission chain drives the crawler template to rotate; after the concrete overflow surface rolling template device moves forward and upward along the track to a vertical height of 30 cm, the deceleration winch is turned off to complete the climbing action; After the climbing action is completed, the pouring action is returned; the pouring action and the climbing action are performed alternately until the concrete pouring of the overflow surface of the starting section is completed; The fifth step is to pour the overflow surface concrete of the main section; When the first layer of concrete on the overflow surface of the starting section reaches the designed demolding strength, the climbing action is performed manually or automatically, and the climbing action and pouring action are performed alternately until the concrete overflow surface rolling formwork device moves forward and upward to the top of the dam overflow surface, completing the pouring of the overflow surface concrete.

5. The construction process according to claim 4, characterized in that: In the third step, a release agent is applied to the outer surface of the rubber belt.

6. The construction process according to claim 4, characterized in that: When the overflow surface width is larger than the maximum width of a single-section rolling formwork, it is divided into multiple sections for construction, and the split side formwork is installed on the side of the dam slope where the pouring position is to be located; each section of construction is carried out according to the first to fifth steps.

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