Casting device and method for steel shell-concrete composite orthotropic bridge deck structure

Abstract

The present invention belongs to the technical field of bridge engineering, and specifically discloses a casting device and method for a steel-shell-concrete composite orthotropic bridge deck structure. It includes a feed hopper, a shaping feed section, a transition section and a vibrator. The vibrator is arranged in multiples along the transverse and longitudinal directions. Multiple vibrators in the transverse direction are synchronized, and the longitudinal direction is vibrated in a zoned variable frequency manner. The frequency of the vibrator is gradually reduced from the bottom to the top, so that the frequency of the vibrator resonates with the fluid concrete mixture to stimulate the thixotropic properties of the fluid concrete, so that the flow rate of the concrete mixture in each section of the steel-shell-concrete composite orthotropic bridge deck structure is equal, and the vibration frequency and flow rate are coordinated, so that the concrete mixture can continue to flow downward evenly and stably. The present invention forms resonance with the inner-fill concrete through reasonable arrangement of the exciter, gives full play to its thixotropic properties, significantly enhances the fluidity of the concrete, and solves the problem of concrete pouring in a narrow space.

Description

Technical Field

[0001] The present invention belongs to the technical field of bridge engineering, and more specifically, relates to a casting device and method for a steel shell-concrete composite orthotropic bridge deck structure. Background Art

[0002] In the modern construction industry, concrete pouring technology is one of the key links. Especially for the steel shell-concrete composite orthotropic bridge deck structure, the pouring process is complex and technically demanding, and has strict requirements on the fluidity and uniformity of the concrete mixture.

[0003] In the prior art, the concrete pouring devices and methods have the following problems: (1) The fluidity and uniformity of the concrete mixture are difficult to ensure: During the pouring process, the concrete mixture needs to flow and be evenly distributed inside the steel shell structure, but the pouring devices in the prior art often find it difficult to achieve this goal. For example, when the existing flat vibrator is in use, the surface of the vibrator is in direct contact with the working cement, and the cement is easy to splash and may enter the motor, affecting the normal operation and service life of the equipment. (2) Exhaust problem during concrete pouring: When pouring composite structures, the bubbles inside the concrete mixture need to be effectively discharged to ensure the density and durability of the concrete. In the prior art, the design of the exhaust channel may not be reasonable enough, resulting in incomplete bubble discharge, affecting the quality of the concrete. (3) The adjustment and control of the pouring device is not intelligent enough: The adjustment and control of the existing pouring device mostly rely on manual operation and lack an intelligent monitoring and adjustment system, which not only increases the complexity of the operation, but also makes it difficult to achieve precise control of the fluidity of the concrete mixture.

[0004] Based on the above defects and shortcomings, the art urgently needs to propose a casting device for a steel shell-concrete composite orthotropic bridge deck structure to uniformly cast the small space of the steel shell-concrete composite orthotropic bridge deck structure, thereby overcoming the problems of difficulty in ensuring fluidity and uniformity and poor exhaust in the prior art. Summary of the invention

[0005] In view of the above defects or improvement needs of the prior art, the present invention provides a casting device and method for a steel shell-concrete composite orthotropic bridge deck structure, which ensures the continuous flow of the concrete mixture from the starting point to the end point of casting through the inclined surface design of the support base, combined with the orderly configuration of the discharge hopper, the shaping discharge section and the transition section. In particular, the multiple T-shaped ribs and core rod steel bars arranged between the transparent top plate and the steel bottom plate of the transition section not only enhance the stability of the structure, but also provide the possibility of real-time observation of the flow state of concrete. In addition, multiple external vibration units are arranged along the inclined surface, and the vibrators thereon effectively stimulate the thixotropic properties of the concrete mixture through synchronous and variable frequency coordinated vibration, thereby promoting its uniform flow during the casting process. The frequency of the vibrator gradually decreases from bottom to top, matching the flow state of the concrete mixture, achieving the coordination of the vibration frequency and the flow velocity, thereby ensuring the continuous, uniform and stable flow of the concrete mixture throughout the entire pouring process. In this way, the requirements for concrete pouring in the narrow space of the steel shell-concrete composite orthotropic bridge deck structure are realized and met, effectively overcoming the flow resistance caused by the complexity of the structure, ensuring the uniformity and stability of the pouring process, and at the same time improving the construction efficiency and the quality of the concrete structure, ensuring that the concrete mixture flows and fills according to predetermined requirements, thereby improving the controllability of the construction process and the accuracy of the concrete structure.

[0006] To achieve the above object, according to one aspect of the present invention, a casting device for a steel shell-concrete composite orthotropic bridge deck structure is provided, comprising:

[0007] A support base with an inclined top surface, the top surface of which is used to place a steel shell concrete composite orthotropic bridge deck structure to be cast;

[0008] A lower hopper disposed on the top of the support base;

[0009] A shaping and unloading section provided at the discharge port of the unloading hopper;

[0010] A transition section is provided at the discharge port of the shaping and unloading section, the transition section comprises a transition section transparent top plate whose top surface is used for real-time observation of the flow state of the internal concrete mixture and a transition section steel bottom plate, a plurality of transition section T-shaped ribs are arranged between the transition section transparent top plate and the transition section steel bottom plate along the longitudinal bridge direction, a plurality of transition section core rod steel bars are arranged in parallel, and all of them pass through the transition section core rod steel bars along the transverse bridge direction;

[0011] A plurality of external vibration units are arranged along the inclined surface and fixed on the support base, and the plurality of external vibration units are arranged in parallel in the horizontal direction. Each of the external vibration units includes a tire frame arranged on the support base and a plurality of vibrators arranged at the bottom of the tire frame. The plurality of vibrators are arranged at intervals laterally along the tire frame, and a plurality of vibrators are arranged along the transverse bridge and longitudinal bridge directions, wherein the multiple vibrators in the transverse bridge direction are synchronized, and the partitioned variable frequency vibration in the longitudinal bridge direction is coordinated, and the vibrator frequency is gradually reduced from the bottom to the top, so that the vibrator frequency resonates with the fluid concrete mixture to stimulate the thixotropic properties of the fluid concrete, so that the flow velocity of the concrete mixture in each section of the steel shell concrete composite orthotropic bridge deck structure is equal, so that the vibration frequency and the flow velocity are coordinated, and the concrete mixture can flow downward continuously, evenly and stably.

[0012] As a further preference, the transition section further comprises a plurality of transition section shear bolt assemblies for connecting the transparent top plate of the transition section and the steel bottom plate of the transition section.

[0013] As a further preferred embodiment, the transition section T-shaped rib is provided with a web circular hole for accommodating the transition section core rod steel bar to pass through, and the face plate of the transition section T-shaped rib is fixedly connected to the transition section steel bottom plate by transition section rivets.

[0014] As a further preferred embodiment, the arrangement spacing of the T-shaped ribs of the transition section along the transverse direction of the bridge is consistent with the T-shaped rib spacing in the steel shell concrete composite orthotropic bridge deck structure, which is 600-800 mm.

[0015] As a further preference, a feed hopper is arranged between each adjacent T-shaped rib of the transition section, and a regulating valve plate for adjusting the flow rate of the concrete mixture is arranged at the discharge port of each feed hopper, so that the concrete mixture of a specified flow rate flows into the corresponding shaping feed section, and under the vibration action of the vibrator at the bottom of the shaping feed section, the concrete mixture is shaped to a specified thickness in the shaping feed section.

[0016] As a further preferred embodiment, a cavity for the flow of concrete mixture is formed between the bottom of the core rod steel bar of the transition section and the top surface of the steel bottom plate of the transition section, and an exhaust channel is formed between the top of the core rod steel bar of the transition section and the bottom surface of the transparent top plate of the transition section.

[0017] As a further preference, the support base includes a plurality of pillars arranged at the bottom of the tire frame.

[0018] As a further preferred embodiment, it further comprises a thickness measuring sensor disposed between the shaping and unloading section and the transition section, the thickness measuring sensor being used to measure the thickness of the concrete mixture flowing into the transition section;

[0019] As a further preferred embodiment, a controller is further included, which is communicatively connected with the lower hopper, the regulating valve plate and the vibrator, and is used for collaboratively adjusting the working parameters of the lower hopper, the regulating valve plate and the vibrator.

[0020] According to another aspect of the present invention, a method for casting a steel shell concrete composite orthotropic bridge deck structure is provided, which is implemented by using a casting device according to the above embodiment or a combination of multiple embodiments, and includes:

[0021] Step 1: The concrete mixture placed in the discharge hopper flows into the shaping discharge section at a specified flow rate, and the vibrator at the bottom of the shaping discharge section applies an exciting force to the concrete mixture to shape the concrete mixture into a specified thickness;

[0022] Step 2: The concrete mixture of the specified thickness enters the transition section, and the vibrator at the bottom of the transition section applies an exciting force to the concrete mixture. Under the combined action of gravity and the exciting force, the concrete mixture of the specified thickness gradually changes from a chaotic flow state to an ideal flow state of uniform and stable flow along the inclined slope direction. In this process, the exhaust channel is kept unobstructed.

[0023] Step 3: The concrete mixture in an ideal flow state flows into the steel shell structure of the steel shell concrete composite orthotropic bridge deck structure located at the bottom of the transition section, and the vibrator on the bottom surface of the steel shell structure applies an exciting force to the concrete mixture in an inclined direction, so that the flow rate of the concrete mixture in each section of the steel shell structure is equal, until the concrete mixture reaches the bottom of the steel shell structure and fills the space between the lower edge of the core rod steel bar and the top surface of the upper steel plate;

[0024] Step 4: The concrete mixture flows to the bottom of the steel shell structure and gradually accumulates to fill the exhaust channel. From bottom to top, as the height of the concrete mixture rises by a specified height, the frequency of the exciting force of the corresponding section is increased. After vibrating for a specified length of time, the output of the exciting force of the corresponding section is stopped to expel internal bubbles until the concrete mixture fills the transition section and the vibrator is turned off.

[0025] As a further preferred embodiment, multiple vibrators are arranged along the transverse and longitudinal directions of the bridge, wherein multiple vibrators in the transverse direction are synchronized, and variable-frequency vibrations are coordinated in the longitudinal direction, and the frequency of the vibrator is gradually reduced from bottom to top, so that the frequency of the vibrator resonates with the fluid concrete mixture to stimulate the thixotropic properties of the fluid concrete, overcome the resistance of the multiple first shear nails arranged in the steel shell structure, and make the flow velocity of the concrete mixture equal in each section, so as to achieve coordination between the vibration frequency and the flow velocity, and the concrete mixture can flow downward continuously, evenly and stably.

[0026] In general, the above technical solution conceived by the present invention has the following technical advantages compared with the prior art:

[0027] 1. The pouring device for inner-filled concrete of the present invention allows the concrete to flow naturally through the inclined steel shell structure. At the same time, through the reasonable arrangement of the exciter, resonance is formed with the inner-filled concrete, and its thixotropic properties are fully exerted, which significantly enhances the fluidity of the concrete and solves the problem of concrete pouring in a narrow space.

[0028] 2. The present invention realizes uniform distribution and continuous and stable flow of concrete mixture in the steel shell concrete composite orthotropic bridge deck structure by arranging multiple external vibration units on the supporting base and adopting the mode of synchronous multi-vibrator in the transverse bridge direction and coordinated vibration in the longitudinal bridge direction. The frequency of the vibrator gradually decreases from the bottom to the top, matching the flow state of the concrete mixture, stimulating the thixotropic performance of the concrete, effectively overcoming the flow resistance caused by the complexity of the structure, and ensuring the uniformity and stability of the pouring process.

[0029] 3. The present invention realizes precise shaping and flow control of concrete mixture by designing the shaping feeding section and transition section in coordination with the external vibration unit. This intelligent pouring method reduces the dependence on manual operation, reduces the construction difficulty, and improves the construction efficiency and the quality of the concrete structure.

[0030] 4. The pouring device of the present invention not only solves the problems of concrete fluidity and uniformity in the prior art, but also improves the intelligent level of construction, reduces construction costs, and has significant economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a front structural schematic diagram of a casting device for a steel shell-concrete composite orthotropic bridge deck structure involved in an embodiment of the present invention;

[0032] Figure 2 yes Figure 1 Schematic diagram of the back structure;

[0033] Figure 3 yes Figure 1 A cross-sectional view along the longitudinal direction;

[0034] Figure 4 yes Figure 1 A cross-sectional view of the transition section involved;

[0035] Figure 5 It is a structural schematic diagram of a steel shell concrete composite orthotropic bridge deck structure involved in an embodiment of the present invention;

[0036] Figure 6 is a structural schematic diagram of a steel shell structure involved in an embodiment of the present invention;

[0037] Figure 7It is a schematic structural diagram of longitudinal and transverse stiffening ribs involved in an embodiment of the present invention;

[0038] Figure 8 It is a schematic diagram of the installation process of a steel shell concrete composite orthotropic bridge deck structure involved in an embodiment of the present invention;

[0039] Fig. 9 is a cross-sectional view in the transverse direction of a steel shell concrete composite orthotropic bridge deck structure involved in an embodiment of the present invention;

[0040] Fig.10 It is a structural schematic diagram of a board end connection structure involved in an embodiment of the present invention.

[0041] In all the drawings, the same reference numerals represent the same technical features, specifically: 100- steel shell structure, 101- upper steel plate, 102- lower steel plate, 102-2- rivet hole, 103- perforated T-shaped rib, 103-1- perforated T-shaped rib web, 103-2- web circular hole, 103-3- flange plate, 103-4- rivet hole, 104- shear bolt assembly, 104-1- first shear bolt, 104-2- rivet hole, 104-3- flange plate, 104-4- rivet hole, 104-5- shear bolt assembly, 104-6- rivet hole, 104-7- rivet hole, 104-8- rivet hole, 104-9- rivet hole, 104-10- rivet hole, 104-11- rivet hole, 104-12- rivet hole, 104-13- rivet hole, 104-14- rivet hole, 104-15- rivet hole, 104-16- rivet hole, 104-17- rivet hole, 104-18- rivet hole, 104-20- rivet hole, 104-21- rivet hole, 104-22- rivet hole, 104-23- rivet hole, 104-24- rivet hole, 104-25- rivet hole, 104-26- rivet hole, 104-27- rivet hole, 104-28- rivet hole, 104-29- rivet hole, 104-30- rivet hole, 104-31- rivet hole 4-2-second shear nail, 105-core steel bar, 106-first rivet, 200-longitudinal and transverse stiffening ribs, 201-transverse stiffening assembly, 201-1-transverse stiffening web, 201-2-transverse stiffening panel, 202-longitudinal stiffening assembly, 202-1-longitudinal stiffening web, 202-2-longitudinal stiffening panel, 300-filled concrete, 400-plate end connection structure, 401-end variable section T-shaped rib, 402- Middle plug plate assembly, 402-1-first middle plug plate, 402-2-second middle plug plate, 402-3-third middle plug plate, 403-middle connecting plate, 404-bottom connecting steel plate, 405-bottom connecting plate opening, 406-weld, 407-second rivet, 408-reinforced concrete, 409-plug plate circular hole, 500-concrete pouring device, 501-discharging hopper, 502-shaping discharging section, 503- regulating valve plate, 504- transition section, 504-1- transparent top plate of transition section, 504-2- steel bottom plate of transition section, 504-3- T-shaped rib of transition section, 504-4- core steel bar of transition section, 504-5- shear bolt assembly of transition section, 505- external vibration unit, 505-1- tire frame, 505-2- vibrator, 506- concrete mixture, 507- exhaust channel, 508- supporting base. DETAILED DESCRIPTION

[0042] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0043] like Figures 1 to 10 As shown, a steel shell-concrete composite orthotropic bridge deck structure provided by an embodiment of the present invention includes a plurality of steel shell-concrete composite orthotropic bridge deck units, each of which includes: a steel shell structure 100, an inner filling concrete 300 arranged in the steel shell structure 100, longitudinal and transverse stiffening ribs 200 arranged at the bottom of the steel shell structure 100, and a plate end connection structure 400 connecting adjacent steel shell-concrete composite orthotropic bridge deck units, wherein the steel shell structure 100 includes an upper steel plate 101, a lower steel plate 102 and a plurality of mandrel steel bars 105 arranged in parallel, a plurality of open T-shaped ribs 103 arranged in parallel along the longitudinal direction of the bridge deck are arranged between the upper steel plate 101 and the lower steel plate 102, and the mandrel steel bars 105 pass through the open T-shaped ribs 103. The steel shell structure 100 further comprises a plurality of shear bolt assemblies 104 for anchoring the upper steel plate 101 and the lower steel plate 102 in the inner-filled concrete 300. The perforated T-shaped rib web 103-1 of the T-shaped stiffening rib 103 is welded to the upper steel plate 101, and the flange plate 103-3 is riveted to the lower steel plate 102, so that the upper steel plate 101 and the lower steel plate 102 attached with the shear bolt assemblies 104 are connected in a narrow space to form a steel shell structure 100 that can bear force together. The reinforced concrete tenons and shear bolt assemblies 104 formed by the perforated T-shaped rib 103 and the core steel bar 105 anchor the upper steel plate 101 and the lower steel plate 102 in the inner-filled concrete 300, so that the steel shell structure 100 and the inner-filled concrete 300 are combined into a steel shell-concrete composite plate that is deformed in a coordinated manner and bears force together. In this embodiment, the upper and lower steel plates attached with shear bolts are connected in a narrow space to form a steel shell structural component that can bear force together; the reinforced concrete tenons and shear bolts formed by the perforated T-shaped ribs and the core rod steel bars anchor the upper and lower steel plates in the inner filling concrete, the T-shaped stiffening ribs reduce the free plate width of the upper and lower steel plates, and together with the shear bolts form a strong constraint on the upper and lower steel plates, ensuring that the upper and lower steel plates do not elastically buckle before the tension and compression yield, so that the material properties of the upper and lower steel plates in the structure are fully utilized; the steel shell structure strongly constrains the inner filling concrete through the closed space, reinforced concrete tenons and shear bolts, thereby improving its crack resistance and crack constraint capacity, effectively improving the performance of the concrete structure, and combining the steel shell structural component with the inner filling concrete to form a steel shell-concrete composite plate with coordinated deformation and common force.

[0044] Based on the above embodiments, in a preferred embodiment of the present invention, the steel shell structure 100 also includes a plurality of shear bolt assemblies 104 for anchoring the upper steel plate 101 and the lower steel plate 102 in the inner-fill concrete 300, and the shear bolt assemblies 104 are used to bear part of the shear force between the upper steel plate 101, the lower steel plate 102 and the inner-fill concrete 300.

[0045] Based on the above-mentioned embodiment or a combination of multiple embodiments, in a preferred embodiment of the present invention, the perforated T-shaped rib 103 includes an integrally formed perforated T-shaped rib web 103-1 and a perforated T-shaped rib flange plate, and the perforated T-shaped rib web 103-1 is provided with a web circular hole 103-2 for accommodating the core rod steel bar 105 to pass through, and the perforated T-shaped rib panel is fixedly connected to the lower steel plate 102 by a first rivet 106.

[0046] Based on the above embodiment or a combination of multiple embodiments, in a preferred embodiment of the present invention, both ends of the core rod steel bar 105 are fixed to the open T-shaped rib web 103-1 at the transverse end of the bridge deck by bolts.

[0047] That is, in the present invention, the inner filling concrete 300 is densely poured in the steel shell structure 100, and the perforated T-shaped rib 103, the core rod steel bar 105 and the inner filling concrete 300 jointly form a reinforced concrete tenon 301, which is used to ensure that the steel shell structure 100 and the inner filling concrete 300 cooperate to bear the external load, and the shear bolt 104 anchors the upper steel plate 101 and the lower steel plate 102 in the inner filling concrete 300, and bears part of the shear force between the upper and lower steel plates and the inner filling concrete 300; the perforated T-shaped rib 103 reduces the upper and lower steel plates. The free width of the plate, the infill concrete 300 strongly constrains the open T-shaped rib 103 so that it does not buckle, and together with the shear bolts 104, forms a strong constraint on the upper and lower steel plates, ensuring that the upper and lower steel plates do not elastically buckle before yielding in tension and compression, so that the material properties of the upper and lower steel plates in the structure are fully utilized; the steel shell structure 100 strongly constrains the infill concrete 300 through the closed space, reinforced concrete tenons 301 and shear bolts 104, improving its crack resistance and crack constraint ability, and effectively improving the performance of the concrete structure. The steel shell structure 100 and the infill concrete 300 form a steel shell-concrete composite plate with coordinated deformation and joint force, so that the properties of the two materials of steel and concrete can be fully utilized, and the structural stiffness and strength are effectively improved.

[0048] Based on the above embodiment or a combination of multiple embodiments, in a preferred embodiment of the present invention, the spacing of the perforated T-shaped rib 103 along the transverse bridge direction is 600-800 mm, the vertical position of the web circular hole 103-2 is in the middle of the perforated T-shaped rib web 103-1, and the longitudinal spacing of adjacent web circular holes 103-2 is 100-300 mm. The opening shape of the web circular hole 103-2 is circular, and the core rod steel bar 105 inserted into the web circular hole 103-2 forms a reinforced concrete tenon 301 with the concrete in the hole.

[0049] Based on the above embodiment or a combination of multiple embodiments, in a preferred embodiment of the present invention, the shear bolt assembly 104 includes an upper steel plate shear bolt 104-1 fixedly connected to the upper steel plate 101 and a lower steel plate shear bolt 104-2 fixedly connected to the lower steel plate 102, the longitudinal and transverse spacings of the upper steel plate shear bolt 104-1 are both 120 to 220 mm, the arrangement spacing of the lower steel plate shear bolt 104-2 is the same as that of the upper steel plate shear bolt 104-1, but the upper steel plate shear bolt 104-1 and the lower steel plate shear bolt 104-2 are arranged in a longitudinal staggered manner, and the longitudinal staggered spacing range is 60 to 110 mm. Specifically, the longitudinal and transverse spacings of the upper steel plate shear nails 104-1 are both 120 to 220 mm, and the spacings of the lower steel plate shear nails 104-2 are the same as those of the upper steel plate shear nails 104-1, but the upper steel plate shear nails 104-1 and the lower steel plate shear nails 104-2 are arranged in an alternate manner in the longitudinal direction.

[0050] Based on the above embodiment or a combination of multiple embodiments, in a preferred embodiment of the present invention, the total thickness of the steel shell structure 100 is 8 to 12 cm, and the thickness of the upper steel plate 101 and the lower steel plate 102 is not greater than 1 / 8 of the thickness of the steel shell structure 100.

[0051] Based on the above embodiment or a combination of multiple embodiments, in a preferred embodiment of the present invention, the inner filling concrete 300 adopts ordinary concrete, high performance concrete, fiber concrete or ultra-high performance concrete according to the force requirements of the steel shell-concrete composite orthotropic bridge deck.

[0052] Based on the above embodiments or a combination of multiple embodiments, in a preferred embodiment of the present invention, the plate end connection structure 400 includes an intermediate plug plate assembly 402 and an intermediate connecting plate 403 arranged on the same horizontal plane, the intermediate plug plate assembly 402 is used to connect the specified core rod steel bars 105 at both ends of the steel shell structure 100 in the horizontal direction, and the intermediate connecting plate 403 is used to connect two adjacent intermediate plug plate assemblies 402. In this way, the connection between the intermediate plug plate 402 and the inner filling concrete 300 is strengthened, so that the intermediate plug plate 402 and the inner filling concrete 300 form a whole working together. At the same time, the intermediate plug plate 402 connects the inner filling concrete 300 of the adjacent steel shell-concrete composite orthotropic bridge deck structure, converts the connection between the concrete into a connection between the steel plates, and eliminates the weak link of the concrete connection. The intermediate plug plate assembly 402 includes a first intermediate plug plate 402-1, a second intermediate plug plate 402-2 and a third intermediate plug plate 402-3 arranged in sequence from the transverse center of the steel shell structure 100 to both ends, wherein one end of the third intermediate plug plate 402-3 is connected to the core bar 105, and the other end is connected to the intermediate connecting plate 403. That is, in this embodiment, the intermediate plug plate assembly 402 is divided into the first intermediate plug plate 402-1, the second intermediate plug plate 402-2 and the third intermediate plug plate 402-3, which are welded to the core bar 105, and a circular hole 409 is opened in the middle of the first intermediate plug plate 402-1, the second intermediate plug plate 402-2 and the third intermediate plug plate 402-3 to form a concrete tenon with the concrete flowing into the holes, further strengthening the connection between the intermediate plug plate 402 and the inner filling concrete 300, so that the intermediate plug plate assembly 402 and the inner filling concrete 300 form a working whole together, and the intermediate plug plate assembly 402 of the adjacent steel shell-concrete composite panels is connected through the middle The connecting plate 403 is welded and connected, so that the middle plug plate assembly 402 is connected to the inner-filled concrete 300 of the adjacent steel shell-concrete composite panels, converting the connection between the concrete into a connection between the steel plates, eliminating the weak link of the concrete connection; the upper steel plates 101 of the adjacent steel shell-concrete composite panels are connected by welds 406; the lower steel plates 102 of the adjacent steel shell-concrete composite panels are connected to the bottom connecting steel plate 404 by pre-pierced bolts; after the above connection is completed, the cavity formed between the upper steel plate 101, the bottom connecting steel plate 404, and the end variable-section T-shaped rib 401 is filled with reinforced concrete 408 to form an internal support constraint.

[0053] Based on the above-mentioned embodiment or a combination of multiple embodiments, in a preferred embodiment of the present invention, the plate end connection structure 400 also includes a weld 406 connecting the two adjacent upper steel plates 101 and a bottom connecting steel plate 404 connecting the two adjacent lower steel plates 102, and the bottom connecting steel plate 404 is fixedly connected to the lower steel plate 102 by a second rivet 407.

[0054] Based on the above-mentioned embodiments or a combination of multiple embodiments, in a preferred embodiment of the present invention, the plate end connection structure 400 also includes an end variable-section T-shaped rib 401, which is arranged at both ends of the open hole T-shaped rib 103 and is integrally formed with the open hole T-shaped rib 103. The end variable-section T-shaped rib 401 is arranged between the upper steel plate 101 and the lower steel plate 102, and an arc-shaped variable section is provided at its end, so that a cavity is formed between the upper steel plate 101, the bottom connecting steel plate 404, and the end variable-section T-shaped rib 401, and the cavity is filled with reinforced concrete 408 to form an internal support constraint.

[0055] Based on the above embodiment or a combination of multiple embodiments, in a preferred embodiment of the present invention, the longitudinal and transverse stiffening ribs 200 include a plurality of transverse stiffening components 201 arranged in parallel in the transverse direction and a plurality of longitudinal stiffening components 202 arranged in parallel in the longitudinal direction. The spacing between adjacent transverse stiffening components 201 is 2000-4000 mm; the spacing between adjacent longitudinal T-shaped stiffening components 201 is 900-1800 mm. In this embodiment, the bottom surface of the steel shell-concrete composite plate is welded to the webs (201-1, 202-1) of the longitudinal and transverse T-shaped stiffening components, and the longitudinal and transverse stiffening (201, 202) further enhances the stiffness of the steel shell-concrete composite plate. Since the height and stiffness of the longitudinal and transverse stiffening (201, 202) can be set respectively, the stiffness of the steel shell-concrete composite plate reinforced by them is different in the longitudinal and transverse directions, so a steel shell-concrete composite orthotropic bridge deck structure is formed.

[0056] In addition, the present invention also provides a casting device for a steel shell-concrete composite orthotropic bridge deck structure, including: a support base 508 with an inclined top surface, and the support base 508 includes a plurality of pillars arranged at the bottom of the tire frame 505-1. The top surface of the support base 508 is used to place the steel shell-concrete composite orthotropic bridge deck structure to be cast; a feed hopper 501 is arranged on the top of the support base; a shaping feed section 502 is arranged at the discharge port of the feed hopper 501; a transition section 504 is arranged at the discharge port of the shaping feed section 502, the transition section 504 includes a transition section transparent top plate 504-1 with a top surface for real-time observation of the flow state of the internal concrete mixture 506 and a transition section steel bottom plate 504-2, a plurality of transition section T-shaped ribs 504-5 are arranged between the transition section transparent top plate 504-1 and the transition section steel bottom plate 504-2 along the longitudinal bridge direction, a plurality of transition section core rod steel bars 504-4 are arranged in parallel, and all pass through the transition section core rod steel bars 504-4 along the transverse bridge direction; a plurality of external vibration units 505 are arranged along the inclined surface and fixedly provided on the support base 508, the plurality of external vibration units The elements 505 are arranged in parallel along the horizontal direction, and each of the external vibration units 505 includes a tire frame 505-1 arranged on the supporting base 508 and a plurality of vibrators 505-2 arranged at the bottom of the tire frame 505-1, the plurality of vibrators 505-2 are arranged at intervals laterally along the tire frame 505-1, and a plurality of vibrators 505-2 are arranged along the transverse bridge and longitudinal bridge directions, wherein the multiple vibrators 505-2 in the transverse bridge direction are synchronized, and the longitudinal bridge direction is partitioned with variable frequency vibration coordination, and the frequency of the vibrator 505-2 is gradually reduced from the bottom to the top, so that the frequency of the vibrator 505-2 resonates with the fluid concrete mixture to stimulate the thixotropic properties of the fluid concrete, so that the flow velocity of the concrete mixture 506 in each section of the steel shell-concrete composite orthotropic bridge deck structure is equal, so that the vibration frequency and the flow velocity are coordinated, and the concrete mixture 506 can continue to flow downward evenly and stably.

[0057] Based on a combination of any of the above embodiments, in this embodiment, the transition section 504 further includes a plurality of transition section shear bolt assemblies 504-5 for connecting the transition section transparent top plate 504-1 and the transition section steel bottom plate 504-2.

[0058] Based on a combination of any of the above embodiments, in this embodiment, the transition section T-shaped rib 504-5 is provided with a web circular hole for accommodating the transition section core rod steel bar 504-4 to pass through, and the panel of the transition section T-shaped rib 504-5 is fixedly connected to the transition section steel bottom plate 504-2 by transition section rivets.

[0059] Based on a combination of any of the above embodiments, in this embodiment, the arrangement spacing of the transition section T-shaped ribs 504-5 along the transverse direction of the bridge is consistent with the T-shaped rib spacing in the steel shell-concrete composite orthotropic bridge deck structure, which is 600-800 mm.

[0060] Based on a combination of any of the above embodiments, in this embodiment, a feed hopper 501 is arranged between each adjacent transition section T-shaped rib 504-5, and a regulating valve plate 503 for adjusting the flow rate of the concrete mixture 506 is arranged at the discharge port of each feed hopper 501, so that the concrete mixture 506 of a specified flow rate flows into the corresponding shaping feed section 502, and under the vibration action of the vibrator 505-2 at the bottom of the shaping feed section 502, the concrete mixture 506 is shaped into a specified thickness in the shaping feed section 502.

[0061] Based on a combination of any of the above embodiments, in this embodiment, a cavity for the flow of concrete mixture 506 is formed between the bottom of the transition section core rod steel bar 504-4 and the top surface of the transition section steel bottom plate 504-2, and an exhaust channel 507 is formed between the top of the transition section core rod steel bar 504-4 and the bottom surface of the transition section transparent top plate 504-1.

[0062] Based on a combination of any of the above embodiments, in this embodiment, a thickness measuring sensor is further included between the shaping and unloading section 502 and the transition section 504, and the thickness measuring sensor is used to measure the thickness of the concrete mixture 506 flowing into the transition section 504. In this embodiment, the thickness of the concrete mixture 506 entering the steel structure is the distance between the bottom of the transition section mandrel steel bar 504-4 and the top surface of the transition section steel bottom plate 504-2. In this way, the concrete mixture 506 is injected into the space between the two adjacent perforated T-shaped ribs 103 at a specified flow rate. Before the concrete mixture 506 is injected into the space between the two adjacent perforated T-shaped ribs 103, the concrete mixture 506 is first shaped into a thin layer of fluid concrete having a thickness not greater than the distance between the lower edge of the core rod steel bar 105 and the top surface of the upper steel plate 101. At this time, an exhaust channel 507 is formed between the upper edge of the core rod steel bar 105 and the top surface of the lower steel plate 102. Then, an exciting force is applied to the thin layer of fluid concrete, so that the thin layer of fluid concrete is gradually transformed from a chaotic flow state to an ideal flow state of uniform and stable flow along the inclined slope direction and flows into the space between the two adjacent perforated T-shaped ribs 103, and the exhaust channel 507 is kept unobstructed. After the thin layer of fluid concrete flows into the space between the two adjacent perforated T-shaped ribs 103 from the ideal flow state, , continue to apply exciting force to the thin layer of fluid concrete in the inclined direction, so that the flow rate of the concrete mixture 506 in each section is equal, until the concrete mixture 506 reaches the bottom of the steel shell structure 100 and fills the space between the lower edge of the core rod steel bar 105 and the top surface of the upper steel plate 101; the concrete mixture 506 flows to the bottom of the steel shell structure 100, gradually accumulates and backfills the exhaust channel 507, and from bottom to top, as the height of the concrete mixture 506 increases by a specified height, the frequency of the exciting force of the corresponding section is increased, and the output of the exciting force of the corresponding section is stopped after vibrating for a specified length of time, so as to discharge the internal bubbles, until the concrete mixture 506 fills the entire exhaust channel 507, and then the concrete mixture 506 is cured to obtain a steel shell-concrete composite orthotropic bridge deck unit.

[0063] Based on the combination of any of the above embodiments, this embodiment also includes a controller, which is communicated with the lower hopper 501, the regulating valve plate 503 and the vibrator 505-2, and is used to coordinately adjust the working parameters of the lower hopper 501, the regulating valve plate 503 and the vibrator 505-2.

[0064] Based on the combination of any of the above embodiments, the present embodiment further includes a plurality of flow rate measuring sensors disposed in the steel shell structure 100 and the transition section 504 for measuring the flow rate of the concrete mixture 506. The flow rate measuring sensors are communicatively connected to the controller for transmitting the measured data to the controller. The controller adjusts the working parameters of the corresponding vibrator in real time according to the data so that the flow rate of the corresponding section meets the set requirements.

[0065] According to another aspect of the present invention, there is also provided a method for casting a steel shell-concrete composite orthotropic bridge deck structure, comprising:

[0066] Step 1: The concrete mixture 506 placed in the discharge hopper 501 flows into the shaping discharge section 502 at a specified flow rate, and the vibrator 505-2 at the bottom of the shaping discharge section 502 applies an exciting force to the concrete mixture 506 to shape the concrete mixture 506 into a specified thickness;

[0067] Step 2: The concrete mixture 506 of the specified thickness enters the transition section 504. The vibrator 505-2 at the bottom of the transition section 504 applies an exciting force to the concrete mixture 506. Under the combined effect of gravity and the exciting force, the concrete mixture 506 of the specified thickness gradually changes from a chaotic flow state to an ideal flow state of uniform and stable flow along the inclined slope direction. In this process, the exhaust channel 507 is kept unobstructed.

[0068] Step 3: The concrete mixture 506 in an ideal flow state flows into the steel shell structure 100 of the steel shell-concrete composite orthotropic bridge deck structure provided at the bottom end of the transition section 504. The vibrator 505-2 on the bottom surface of the steel shell structure 100 applies an exciting force to the concrete mixture 506 along an inclined direction, so that the flow rate of the concrete mixture 506 in each section of the steel shell structure 100 is equal, until the concrete mixture 506 reaches the bottom of the steel shell structure 100 and fills the space between the lower edge of the core rod steel bar 105 and the top surface of the upper steel plate 101.

[0069] Step 4: The concrete mixture 506 flows to the bottom of the steel shell structure 100 and gradually accumulates to fill the exhaust channel 507. From bottom to top, as the height of the concrete mixture 506 increases by a specified height, the frequency of the exciting force of the corresponding section is increased. After vibrating for a specified length of time, the output of the exciting force of the corresponding section is stopped to expel the internal bubbles until the concrete mixture 506 fills the transition section 504 and the vibrator 505-2 is turned off.

[0070] Based on the combination of any of the above embodiments, in this embodiment, multiple vibrators 505-2 are arranged along the transverse bridge and longitudinal bridge directions, wherein multiple vibrators 505-2 in the transverse bridge direction are synchronized, and the longitudinal bridge direction is partitioned with variable frequency vibration and coordinated, and the frequency of the vibrator 505-2 is gradually reduced from bottom to top, so that the frequency of the vibrator 505-2 resonates with the fluid concrete mixture to stimulate the thixotropic properties of the fluid concrete, overcome the resistance of the multiple first shear nails 104-1 arranged in the steel shell structure 100, and make the flow velocity of the concrete mixture 506 equal in each section, so as to achieve the coordination of vibration frequency and flow velocity, and the concrete mixture 506 can continue to flow downward evenly and stably.

[0071] Specifically, the steel structure assembly is placed on an inclined bracket, and the upper steel plate is placed at the bottom, and the T-shaped stiffener is placed at the top. The lower hopper 501, the shaped lowering section 502, the transition section 504 and the steel structure assembly are connected in sequence from top to bottom. After the concrete mixture 506 enters the lower hopper 501, the flow rate is controlled by adjusting the valve plate 503, and flows through the shaped lowering section 502. The concrete mixture 506 entering the lower hopper in batches is shaped into a thin layer of fluid concrete with a thickness not greater than the distance between the lower edge of the core rod steel bar 105 and the top surface of the upper steel plate 101, and naturally flows into the transition section 504 along the inclined slope. A high-frequency vibration unit is arranged in the transition section. After the concrete mixture 506 enters the transition section 504, under the combined effect of gravity and the exciting force of the external vibration unit 505, it overcomes the resistance of the upper steel plate shear nails 104-1 and continues to flow, and gradually transforms the thin layer of flow concrete from a chaotic flow state to an ideal flow state of uniform and stable flow along the inclined slope direction, while keeping the exhaust channel 507 between the concrete mixture 506 and the bottom steel plate 102 unobstructed. The concrete mixture enters the steel shell structure 100 in an ideal flow state, and a vibration unit 505 is arranged at the bottom of the upper steel plate 101. The arrangement of the external vibration unit 505 is as follows: multiple vibration units are synchronized in the horizontal direction and variable frequency vibration is coordinated in the vertical direction. The frequency of the external vibration unit 505 is gradually reduced from the bottom to the top, so that it resonates with the fluid concrete mixture, stimulates the thixotropic property of the fluid concrete, overcomes the resistance of the upper steel plate shear nails 104-1, and makes the flow velocity of the concrete mixture 506 equal in each section, so as to achieve the coordination of vibration frequency and flow velocity. The concrete mixture 506 can continue to flow downward evenly and stably until the concrete mixture 506 reaches the bottom of the steel shell structure 100 and fills the space between the lower edge of the core rod steel bar 105 and the top surface of the upper steel plate 101. During this process, all external vibration units 505 remain in the open state. The concrete mixture 506 flows to the bottom of the steel shell structure 100, gradually accumulates and backfills the exhaust channel 507. From bottom to top, as the liquid level of the concrete mixture rises by 1m, the frequency of the external vibration unit 505 of the corresponding section is adjusted to high frequency, and the vibration stops automatically after 30s. The internal bubbles are discharged by high-frequency excitation force to achieve the effect of dense exhaust. As the material surface rises, the external vibration unit 505 is gradually closed from bottom to top. The regulating valve 503 is kept open to gradually backfill the liquid level of the concrete mixture 506 until the transition section 504 is filled. All external vibration units 505 are closed, the transition section 504 is removed, and the internal concrete mixture is poured out to avoid all defects accumulated at the end of the bridge deck and retain all concrete mixtures 506 in the steel shell structure component; the transition section 504 can be reused after washing after the steel shell-concrete orthotropic composite bridge deck unit is completed. When the concrete age meets the strength requirements for lifting and dismantling, the cast steel shell-concrete orthotropic composite bridge deck will be lifted off the casting platform and enter the maintenance phase.

[0072] It will be easily understood by those skilled in the art that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A casting device for a steel shell-concrete composite orthotropic bridge deck structure, characterized in that: include: A support base (508) with an inclined top surface, the top surface of the support base (508) is used to place a steel shell-concrete composite orthotropic bridge deck structure to be cast; A lower hopper (501) disposed on the top of the support base; A shaping unloading section (502) provided at the discharge port of the unloading hopper (501); A transition section (504) is arranged at the discharge port of the shaping and unloading section (502), the transition section (504) comprising a transition section transparent top plate (504-1) whose top surface is used for real-time observation of the flow state of the internal concrete mixture (506) and a transition section steel bottom plate (504-2), a plurality of transition section T-shaped ribs (504-5) are arranged between the transition section transparent top plate (504-1) and the transition section steel bottom plate (504-2) along the longitudinal bridge direction, and a plurality of transition section mandrel steel bars (504-4) are arranged in parallel and pass through the transition section T-shaped ribs (504-5) along the transverse bridge direction; A cavity for the concrete mixture (506) to flow is formed between the bottom of the transition section core rod steel bar (504-4) and the top surface of the transition section steel bottom plate (504-2), and an exhaust channel (507) is formed between the top of the transition section core rod steel bar (504-4) and the bottom surface of the transition section transparent top plate (504-1); A plurality of external vibration units (505) are arranged along the inclined surface and fixedly mounted on the support base (508); the plurality of external vibration units (505) are arranged in parallel in the horizontal direction; each of the external vibration units (505) comprises a tire frame (505-1) mounted on the support base (508) and a plurality of vibrators (505-2) mounted at the bottom of the tire frame (505-1); the plurality of vibrators (505-2) are arranged at intervals laterally along the tire frame (505-1); and the vibrators (505-2) are arranged along the cross bridge and Multiple vibrators (505-2) are arranged in the longitudinal direction of the bridge, wherein multiple vibrators (505-2) are synchronized in the transverse direction of the bridge and vibrate in coordination with variable frequencies in the longitudinal direction of the bridge. The frequency of the vibrator (505-2) is gradually reduced from the bottom to the top, so that the frequency of the vibrator (505-2) resonates with the fluid concrete mixture to stimulate the thixotropic properties of the fluid concrete, so that the flow velocity of the concrete mixture (506) in each section of the steel shell-concrete composite orthotropic bridge deck structure is equal, and the coordination of the vibration frequency and the flow velocity is achieved, so that the concrete mixture (506) can continue to flow downward evenly and stably.

2. The casting device of the steel shell-concrete composite orthotropic bridge deck structure according to claim 1 is characterized in that: The transition section (504) further comprises a plurality of transition section shear bolt assemblies for connecting the transition section transparent top plate (504-1) and the transition section steel bottom plate (504-2).

3. The casting device of the steel shell-concrete composite orthotropic bridge deck structure according to claim 1 is characterized in that: The transition section T-shaped rib (504-5) is provided with a web circular hole for accommodating the transition section mandrel steel bar (504-4) to pass through, and the face plate of the transition section T-shaped rib (504-5) is fixedly connected to the transition section steel bottom plate (504-2) via transition section rivets.

4. The casting device of the steel shell-concrete composite orthotropic bridge deck structure according to claim 3 is characterized in that: The arrangement spacing of the transition section T-shaped ribs (504-5) along the transverse direction of the bridge is consistent with the T-shaped rib spacing in the steel shell-concrete composite orthotropic bridge deck structure, which is 600-800 mm.

5. The casting device of the steel shell-concrete composite orthotropic bridge deck structure according to claim 1 is characterized in that: A feed hopper (501) is arranged between each adjacent transition section T-shaped rib (504-5), and a regulating valve plate (503) for regulating the flow rate of a concrete mixture (506) is arranged at the discharge port of each feed hopper (501), so that a concrete mixture (506) of a specified flow rate flows into the corresponding shaping feed section (502), and under the vibration action of a vibrator (505-2) at the bottom of the shaping feed section (502), the concrete mixture (506) is shaped into a specified thickness in the shaping feed section (502).

6. The casting device of the steel shell-concrete composite orthotropic bridge deck structure according to claim 1 is characterized in that: The support base (508) includes a plurality of pillars arranged at the bottom of the tire frame (505-1).

7. A casting device for a steel shell-concrete composite orthotropic bridge deck structure according to any one of claims 1 to 6, characterized in that: It also includes a thickness measuring sensor disposed between the shaping and unloading section (502) and the transition section (504), the thickness measuring sensor being used to measure the thickness of the concrete mixture (506) flowing into the transition section (504); It also includes a controller which is in communication with the lower hopper (501), the regulating valve plate (503) and the vibrator (505-2) and is used to coordinately adjust the working parameters of the lower hopper (501), the regulating valve plate (503) and the vibrator (505-2).

8. A method for casting a steel shell-concrete composite orthotropic bridge deck structure, characterized in that: The method is implemented by using the pouring device according to any one of claims 1 to 7, comprising: Step 1: The concrete mixture (506) placed in the discharge hopper (501) flows into the shaping discharge section (502) at a specified flow rate, and the vibrator (505-2) at the bottom of the shaping discharge section (502) applies an exciting force to the concrete mixture (506) to shape the concrete mixture (506) into a specified thickness; Step 2: The concrete mixture (506) of a specified thickness enters the transition section (504), and the vibrator (505-2) at the bottom of the transition section (504) applies an exciting force to the concrete mixture (506). Under the combined action of gravity and the exciting force, the concrete mixture (506) of the specified thickness gradually transforms from a chaotic flow state to an ideal flow state of uniform and stable flow along the inclined slope direction. During this process, the exhaust passage (507) is kept unobstructed. Step 3: The concrete mixture (506) in an ideal flow state flows into the steel shell structure (100) of the steel shell-concrete composite orthotropic bridge deck structure located at the bottom of the transition section (504), and the vibrator (505-2) on the bottom surface of the steel shell structure (100) applies an exciting force to the concrete mixture (506) in an inclined direction, so that the flow rate of the concrete mixture (506) in each section of the steel shell structure (100) is equal, until the concrete mixture (506) reaches the bottom of the steel shell structure (100) and fills the space between the lower edge of the core rod steel bar (105) and the top surface of the upper steel plate (101); Step 4: The concrete mixture (506) flows to the bottom of the steel shell structure (100) and gradually accumulates to fill the exhaust channel (507). From bottom to top, as the height of the concrete mixture (506) increases by a specified height, the frequency of the exciting force of the corresponding section is increased. After vibrating for a specified time, the output of the exciting force of the corresponding section is stopped to discharge the internal bubbles until the concrete mixture (506) fills the transition section (504) and the vibrator (505-2) is turned off.

9. The method for casting a steel shell-concrete composite orthotropic bridge deck structure according to claim 8, characterized in that: The vibrators (505-2) are arranged in plurality along the transverse and longitudinal directions, wherein the multiple vibrators (505-2) in the transverse direction are synchronized and the vibrators (505-2) in the longitudinal direction are vibrated in a coordinated manner with variable frequencies in different sections, and the frequency of the vibrators (505-2) is gradually reduced from the bottom to the top, so that the frequency of the vibrators (505-2) resonates with the fluid concrete mixture to stimulate the thixotropic properties of the fluid concrete, overcome the resistance of the plurality of first shear nails (104-1) arranged in the steel shell structure (100), and make the flow velocity of the concrete mixture (506) equal in each section, so as to achieve coordination between the vibration frequency and the flow velocity, and the concrete mixture (506) can flow downward continuously, evenly and stably.

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