Automated production line for coarse aggregate ultra-high performance concrete bridge deck and control method thereof

Abstract

The present invention proposes an automated production line for coarse aggregate ultra-high performance concrete bridge deck and a control method thereof, which belongs to the technical field of bridge deck prefabrication. The production line of the present invention includes a raw material premixing area, a steel skeleton forming area, a mixture pouring area, a product curing area and a control center. The control center uniformly dispatches and controls the four partitions, and each area can be controlled separately by a sub-controller. Based on the integration of multi-equipment cross-operation of material characteristics and multi-process connection, combined with the bridge deck production task, the automated and intelligent steel fiber feeding, concrete mixing, concrete pouring, and vibrating equipment are used, and each construction process is connected in series in an assembly line manner, and a reasonable arrangement is made to establish an economical, reasonable, and efficient industrialized bridge deck manufacturing production line.

Description

Technical Field

[0001] The present invention relates to the technical field of bridge deck prefabrication, and in particular to an automated production line for coarse aggregate ultra-high performance concrete bridge deck and a control method thereof. Background Art

[0002] With the continuous innovation of bridge engineering technology and the in-depth implementation of the "Strong Transportation Country" and "Dual Carbon" strategies, CA-RP C ultra-high performance bridge deck has gradually become a new favorite in the field of bridge construction due to its excellent material performance and environmental protection advantages. The bridge deck is prefabricated in the factory using coarse aggregate active powder concrete, which can achieve superior product performance such as light weight, high compressive strength and strong toughness with very little material consumption, making the product more convenient, timely, environmentally friendly and replaceable in practical application. It not only realizes the efficient use of materials, but also significantly improves the mechanical properties and construction efficiency of the bridge deck. However, due to the complexity of its production process and high precision requirements, there are few existing production line design cases and the design difficulty is relatively high. This paper aims to explore the design of CA-RPC ultra-high performance bridge deck production line in order to provide technical reference for actual production. Summary of the invention

[0003] The object of the present invention is to provide an automated production line for coarse aggregate ultra-high performance concrete bridge deck and a control method thereof, so as to solve the above-mentioned problems of the prior art.

[0004] To achieve the above object, the present invention provides the following technical solutions:

[0005] An automated production line for coarse aggregate ultra-high performance concrete bridge deck, characterized in that it includes a raw material premixing area, a steel skeleton forming area, a mixture pouring area, a product curing area and a control center;

[0006] The raw material premixing area is provided with a drying system, a three-dimensional storage system, a dry mix batching system, a core powder batching system and a stirring system in order of processing. The three-dimensional storage system includes a batching conveying system and a three-dimensional storage warehouse. The drying system is connected to the three-dimensional storage warehouse through a conveyor belt. A three-level metering device is provided under the three-dimensional storage warehouse to measure each raw material and send it to the dry mixing main machine of the dry mix batching system through the batching conveying system. The dry mix batching system, the core powder batching system and the stirring system are all connected through a feeding circulation system.

[0007] The steel skeleton forming area includes a steel skeleton processing line, a prefabricated board formwork system and a traction drive system. Before or at the same time as the mixed material is obtained in the raw material premixing area, the steel skeleton processing line and the prefabricated board formwork system cooperate to complete the steel skeleton into the mold, and the formwork is pulled from the bottom of the mixing system to the material distribution station of the mixed material pouring area by the traction drive system;

[0008] In the mixing material pouring area, a material distribution system, a row-array leveling integrated machine, a row-type vibrator and a flat plate vibrator and leveler are sequentially arranged along the length direction of the bridge deck. The material distribution system is arranged on the material distribution station. A leveler is arranged at the material discharging port of the material distribution system. The leveler automatically follows the material distribution system to perform horizontal leveling. The material distribution leveling process is closely followed by the exhaust and leveling process. The row-array leveling integrated machine completes the first exhaust and leveling process, and the mold platform is pulled to the exhaust and slurry raising station for resting first, and then the row-type vibrator and the flat plate vibrator and leveler jointly vibrate to perform the second exhaust and leveling process.

[0009] The product curing area includes multiple independent curing kilns, each of which is equipped with a temperature and humidity sensor, a steam heating system and a water spray system, all of which are intelligently controlled by a control center. The mold platform enters the curing kiln through the shuttle bus of the overall ferry system. After curing, the mold platform is moved to the demolding station by the shuttle bus for demolding and cleaning.

[0010] Preferably, it also includes a human-machine interaction interface module, and the control center is composed of four sub-controllers and a main controller that respectively control the raw material premixing area, the steel skeleton forming area, the mixture pouring area and the product curing area. The human-machine interaction interface module is connected to the main controller. The main controller schedules and controls the production line as a whole, collects the working status information of the one or more sub-controllers, and combines the parameter information input by the human-machine interaction interface module, performs internal control logic analysis and database variable processing, and then outputs the generated overall status information of the production line to the human-machine interaction interface module for display, and at the same time sends control instructions to the one or four sub-controllers to control the equipment in the raw material premixing area, the steel skeleton forming area, the mixture pouring area and the product curing area on the production line separately or simultaneously.

[0011] Preferably, the feeding circulation system includes a circular track and a plurality of feeding trolleys, the circular track extends at the height of each discharge port of the dry mix batching system, the core powder batching system and the stirring system arranged in the raw material premixing area, and is enclosed to form a closed L-shaped circular structure, the circular track is evenly supported by a plurality of frame sections, and a plurality of feeding trolleys are arranged on the circular track, and the control system controls the feeding trolleys to move on the circular track to complete the delivery and reception of the dry mix batching system, the core powder batching system and the stirring system.

[0012] Preferably, the material distribution system comprises a material distribution trolley, a material distribution hopper and a traveling frame with tracks. The traveling frame is set up on the material distribution station, and the material distribution trolley automatically moves along the tracks on the traveling frame. The material distribution trolley is provided with an automatically flipping material distribution hopper, which is controlled by a control system to reach the discharge port below the mixing system to receive the material, as well as the movements of moving, unloading and returning.

[0013] Preferably, the mixture pouring area is provided with a constant temperature and humidity system, and the constant temperature and humidity system adopts an industrial air-conditioning system.

[0014] Preferably, the mixing system includes a mixing station, a cantilever lifting device and a steel fiber feeding system. The dry powder mixture from the dry powder batching system is delivered to the mixing station by a feeding trolley along the track. The cantilever lifting device is arranged below the steel fiber feeding system, and the upper end of the steel fiber feeding system is connected to the feed port of the mixing station.

[0015] The control method for an automated production line of a coarse aggregate ultra-high performance concrete bridge deck comprises the following steps:

[0016] S100, preparation before control: selecting a corresponding workstation layout diagram and processing technical parameter programming in the control center according to the type of bridge deck, and the main controller of the control center controls the production process according to the production plan and the selected program;

[0017] S200, raw material premixing zone control: prepare raw materials and fine powder materials, the main controller sends a signal to the raw material premixing zone sub-controller to start each device, each raw material is dried by the drying system to reach the design parameters and then stored separately, the measured raw materials are transported to the dry mixing host according to the raw material ratio for the first mixing, cement is added for the second mixing to obtain a dry powder mixture, the fine powder material and the dry powder premix are sent to the mixing system together by a feeding trolley, water is added for the third mixing, and steel fiber is continuously added for mixing to obtain a mixture;

[0018] S300, steel frame forming area control: the main controller sends out a signal for mold assembly and steel frame mold entry, and completes the steel frame mold entry, i.e., the prefabricated board mold platform, before or at the same time as the mixed material is obtained;

[0019] S400, control of the mixture pouring area: the main controller sends out a material distribution signal, pulls the precast panel formwork to the material distribution station, and the sub-controller starts the material distribution system at the material distribution station to carry out material distribution according to the material distribution path and sequence, sets the corresponding weight of the mixture and the distribution speed required for the bridge deck type, controls the material distribution trolley to drive to the bottom of the mixing system discharge port to receive the mixture, starts to distribute and level the mixture, and then the row-type leveling machine completes the first exhaust and leveling work, rests for a while, and controls the row-type vibrator and the flat plate vibrator and leveling machine to jointly vibrate and carry out the second exhaust and leveling work;

[0020] S500, product curing area control: the main controller sends out a curing signal, the shuttle bus will deliver the mold platform that has completed the previous process into the curing kiln, collect signals through the temperature and humidity sensors, and the sub-controller will control the steam heating system and the water spray system to perform curing work. The curing time in the kiln is 12h~36h, the curing temperature is 80~95℃, and the curing humidity is ≥90%. The shuttle bus will transfer the mold platform that has completed the previous process to the demolding station for demolding and cleaning. After demolding, the bridge panel will be hoisted to the water curing pool for immersion curing for 15~18 days, and a timed automatic drip irrigation curing device will be used for moisturizing curing.

[0021] Preferably, the steel skeleton is installed and tied into the mold based on the end mold and the core mold in the prefabricated plate mold platform system, and the prefabricated steel cage is integrated with the end mold and the core mold so that it can be transported to the prefabricated mold platform as a whole. The prefabricated steel cage is formed by tying the longitudinal and transverse steel bars of the top steel mesh and the bottom steel mesh.

[0022] Preferably, the material distribution path and sequence are divided into n strips according to the pouring direction of the bridge deck. The first strip completes material distribution and leveling, and the row vibrator and the flat plate vibrator and leveler are started to jointly vibrate, exhaust, level and compact. The remaining strips are operated continuously in the order of the first strip distribution until the material distribution, leveling and exhaust and leveling work of all strips are completed. After the first exhaust and leveling work is completed and rested for a while, the mold platform is pulled as a whole to the exhaust and slurry lifting station for an exhaust and leveling work as a whole to complete the said first material distribution; wherein, the vibration frequency of the second exhaust and leveling work is greater than the vibration frequency of the first row leveling action.

[0023] Furthermore, the one-time cloth is completed for the n strips, wherein each strip is clothed twice, the weight of the first cloth accounts for 2 / 3 of the weight of each strip, and the second cloth accounts for 1 / 3 of the weight of each strip, and the overlap between two adjacent strips is 80 to 120 mm.

[0024] In summary, compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The main controller of the control center is responsible for the scheduling and control of the entire production line, and coordinates the work of each link according to the production plan and preset procedures. Each area (such as raw material premixing area, steel skeleton forming area, mixture pouring area, product curing area) is equipped with a sub-controller, which is responsible for equipment control and parameter adjustment in their respective areas and exchanges information with the main controller. Intelligent sensors are installed in key areas such as raw material premixing area, mixture pouring area, product curing area, etc. to monitor key parameters such as temperature, humidity, pressure, etc. in real time, and transmit data to the control center for analysis and processing. The control center automatically adjusts the process parameters according to the monitoring results to ensure the stability and consistency of product quality.

[0026] 2. Raw material premixing area According to the characteristics of raw materials, raw materials are mixed and finely controlled in multiple times. Through multiple mixing processes of dry mix batching system, core powder batching system and stirring system, it is ensured that each component in the mixture is fully mixed and uniform, which helps to improve the physical properties and durability of the bridge deck. Aggregates are pretreated through drying system and dust removal system, and raw materials are effectively managed by using three-dimensional storage system and three-level metering device. Then, through screening dry mixing equipment, raw material waste is reduced, resource utilization is improved, and refined production process and quality control standards are realized.

[0027] 3. The mixing material pouring area has an efficient material distribution and vibration system. The prefabricated plate formwork system is used to accurately position and fix the steel skeleton to ensure the stability and accuracy of the steel skeleton during the pouring process. The material distribution uniformity and the density of the concrete are achieved through the joint work of the material distribution system, row vibrator and flat plate vibrator leveler. The material distribution system can flexibly adjust the material distribution path and sequence according to the pouring direction of the bridge deck, while the vibration system uses high-frequency vibration to expel bubbles in the concrete and make it dense.

[0028] 4. The product curing area is equipped with multiple independent curing kilns, each of which is equipped with temperature and humidity sensors and steam heating systems. The control center uses intelligent algorithms to accurately control the temperature and humidity in the curing kiln to ensure the stability and consistency of the curing conditions. After demolding and during the pool curing stage, an automatic drip irrigation curing device is used to moisturize the bridge deck. It can drip water to the surface of the bridge deck in a regular and quantitative manner to keep its surface moist, which helps prevent concrete cracking and improve its durability. The production line focuses on energy conservation and environmental protection during design and operation, and reduces energy consumption and carbon emissions by accurately controlling the temperature, humidity and curing time during the curing process.

[0029] 5. In the overall production line of the present invention, the equipment for dispersing steel fiber feeding, mixing, distributing, pouring and vibrating concrete can be fully automated, the production rhythm is stable, and the production efficiency and quality of components are well guaranteed. The production line control is based on material characteristics and the connection of multiple processes, and a topological relationship of cross-operation of multiple equipment is established. The CNC automated CA-RPC bridge panel production line is integrated and arranged. The production line layout is reasonable, and the functions of each area are clear, which realizes continuous and smooth production from raw materials to finished products, helps to shorten the production cycle and improve production efficiency. The control center can flexibly adjust the workstation layout and processing technical parameters according to the needs of different bridge panel types to meet diverse production needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 Layout diagram of the automated production line for coarse aggregate ultra-high performance concrete bridge decks;

[0031] Figure 2Layout of the raw material premixing area of ​​the automated production line for coarse aggregate ultra-high performance concrete bridge decks;

[0032] Figure 3 Layout of the mix pouring area for the automated production line for coarse aggregate ultra-high performance concrete bridge decks;

[0033] Figure 4 This is a schematic diagram of the control center structure of the automated production line for coarse aggregate ultra-high performance concrete bridge decks;

[0034] In the figure, 1-raw material premixing area, 10-mixing system, 2-rebar skeleton forming area, 20-mold platform, 3-mixture pouring area, 30-distribution system, 4-product curing area, 40-curing kiln, 5-control center, 6-integrated ferry system, 60-ferry vehicle. DETAILED DESCRIPTION

[0035] The specific embodiments of the present invention are described in detail below in conjunction with the accompanying drawings. It should be understood that the specific embodiments given here are only used to illustrate and explain the present invention, and cannot be used to limit the present invention.

[0036] It should be noted that many specific details are set forth in the following description to facilitate a full understanding of the present invention. However, the present invention may also have other implementations and variations thereof. Therefore, the protection scope of the present invention is not limited to the specific embodiments disclosed below.

[0037] This embodiment is applied to the CA-RPC bridge deck production line of the Shiziyang project. The whole bridge deck has multiple types of bridge decks. It is specifically applied to a single bridge deck with a design length of 14.5m. The bridge deck width is 3.5m, the average thickness of the bridge deck is 0.18m, and the design calculation of the amount of concrete required for a single bridge deck is 9.1㎡. It is specifically used for the automated production line of coarse aggregate ultra-high performance concrete bridge decks, including a raw material premixing area 1, a steel skeleton forming area 2, a mixture pouring area 3, a product curing area 4 and a control center 5;

[0038] The raw material premixing area 1 is provided with a drying system, a three-dimensional storage system, a dry mix batching system, a core powder batching system and a stirring system 10 in order of processing. The three-dimensional storage system includes a batching conveying system and a three-dimensional storage warehouse. The drying system is connected to the three-dimensional storage warehouse through a conveyor belt. A three-level metering device is provided under the three-dimensional storage warehouse to measure each raw material and send it to the dry mixing main machine of the dry mix batching system through the batching conveying system. The dry mix batching system, the core powder batching system and the stirring system 10 are all connected through a feeding circulation system.

[0039] The steel skeleton forming area 2 includes a steel skeleton processing line, a precast plate formwork system and a traction drive system. Before or at the same time as the raw material premixing area 1 obtains the mixed material, the steel skeleton processing line and the precast plate formwork system cooperate to complete the steel skeleton into the mold, and the formwork 20 is pulled from the bottom of the mixing system 10 to the material distribution station of the mixed material pouring area by the traction drive system;

[0040] The above-mentioned formwork is a formwork for precise positioning of prefabricated steel components and positioning, tensioning and anchoring of steel bars. Prefabricated bridge panels are prefabricated using the above-mentioned formwork. The geometric relationship between each prefabricated panel is established by relying on the formwork at the four ends. Prefabrication is completed under the same positioning system to ensure that the steel bars between each prefabricated bridge panel block are accurately positioned and connected smoothly.

[0041] In the mixture pouring area 3, a material distribution system 30, a row-array leveling integrated machine, a row-type vibrator and a flat plate vibrator and leveler are sequentially arranged along the length direction of the bridge deck. The material distribution system 30 is arranged on the material distribution station. A leveler is arranged at the material distribution system discharge port. The leveler automatically follows the material distribution system 30 to perform horizontal leveling. The material distribution leveling process is closely followed by the exhaust and leveling process. The row-array leveling integrated machine completes the first exhaust and leveling process, and the mold platform 20 is pulled to the exhaust and slurry raising station for resting first, and then the row-type vibrator and the flat plate vibrator and leveler are combined to perform the second exhaust and leveling process.

[0042] After re-vibration and leveling, an automatic rolling and laminating machine is used to cover the surface of the mixed material with a plastic film to prevent cracking caused by water loss in the plastic stage.

[0043] The product curing area 4 includes a plurality of independent curing kilns 40, each of which is equipped with a temperature and humidity sensor, a steam heating system and a water spraying system, all of which are intelligently controlled by a control center. The mold platform enters the curing kiln 40 through a shuttle bus 60 of an integral ferry system 6. After curing, the mold platform 20 is moved by the shuttle bus 60 to the demolding station in the demolding area for demolding and cleaning.

[0044] Preferably, it also includes a human-machine interaction interface module, and the control center 5 is composed of four sub-controllers and a main controller that respectively control the raw material premixing area 1, the steel skeleton forming area 2, the mixture pouring area 3 and the product curing area 4. The human-machine interaction interface module is connected to the main controller. The main controller schedules and controls the production line as a whole, collects the working status information of the one or more sub-controllers, and combines the parameter information input by the human-machine interaction interface module, performs internal control logic analysis and database variable processing, and then outputs the generated overall status information of the production line to the human-machine interaction interface module for display, and at the same time sends control instructions to the one or four sub-controllers to control the equipment in the raw material premixing area 1, the steel skeleton forming area 2, the mixture pouring area 3 and the product curing area 4 on the production line separately or simultaneously.

[0045] Preferably, the feeding circulation system includes a circular track and a plurality of feeding trolleys, the circular track extends at the height of each discharge port of the dry mix batching system, the core powder batching system and the stirring system 10 arranged in the raw material premixing area 1, and is enclosed to form a closed L-shaped circular structure, the circular track is evenly supported by a plurality of frame sections, and a plurality of feeding trolleys are arranged on the circular track, and the control system controls the feeding trolleys to move on the circular track to complete the delivery of materials to the dry mix batching system, the core powder batching system and the stirring system 10.

[0046] Preferably, the material distribution system 30 includes a material distribution cart, a material distribution hopper and a traveling frame with tracks. The traveling frame is set up on the material distribution station, and the material distribution cart automatically moves along the tracks on the traveling frame. The material distribution cart is provided with an automatically flipping material distribution hopper, which is controlled by a control system to reach the discharge port below the mixing system 10 to receive the material, as well as the actions of moving, unloading and returning.

[0047] In this embodiment, the material distribution system 30 has a precise material distribution function, which can automatically adjust the size of the material distribution door opening according to the amount of mixed material discharge required for pouring, and match it with the travel speed of the material distribution equipment to achieve precise material distribution. The material distribution trolley has a self-propelled function and can move along the track. The track is a customized mechanical rack with precise movement. There is no need for a gantry crane to lift from the mixer to the production line; the material distribution trolley moves along the short side of the mold and distributes the material in strips. The material distribution width (i.e., the strip width) is the amount of concrete mixed by the mixer at one time. The material distribution time for each strip is 120 to 180 seconds.

[0048] The material distribution hopper of the material distribution system 30 can move along the material distribution direction, so that the material distribution hopper can reach any position required for pouring. The material distribution hopper is provided with a tooth roller, an attached vibrator and a scraper device inside the hopper to make material distribution smooth. The material distribution adopts a flipping type material distribution, and the material distribution is completed at the same time as the material distribution hopper flips. The scraper device inside the hopper is a vibrating scraper with adjustable height on both sides of the material distribution hopper to preliminarily level the mixed material distributed on the steel cage. The distance between the bottom of the vibrating scraper and the top surface of the mold is 12 to 27 mm, which plays a role in controlling the material distribution thickness. The material output is controlled by the speed of the six-blade star wheel and the travel speed of the material distribution hopper, and a weighing detection sensor and a material distribution speed sensor are configured to achieve uniform material distribution. With the cooperation of the scraper, the thickness of the mixed material after distribution is not less than the design thickness of the bridge deck, nor greater than 10 mm of the design thickness of the bridge deck. The spreading width of each bucket of the mixed material is preferably 1.2m to 1.6m. In addition, the material distribution hopper is lined with wear-resistant polytetrafluoroethylene material, which does not stick to concrete and is easy to clean.

[0049] The working process of the material distribution trolley is as follows: the trolley receives the material from the mixer outlet, transports the material to the top of the material distribution system 30, turns over and discharges the material to the material distribution hopper, and then returns to the material distribution outlet of the mixing system 10 to wait for the next batch of concrete mixing to be completed. The material receiving, running, unloading and returning of the material distribution trolley are all completely controlled by the program and completed automatically.

[0050] Preferably, the mixture pouring area is provided with a constant temperature and humidity system, and the constant temperature and humidity system adopts an industrial air-conditioning system.

[0051] Preferably, the mixing system 10 includes a mixing station, a cantilever hoisting device and a steel fiber feeding system. The dry powder mixed material after the dry powder batching system is sent to the mixing station by a feeding trolley along the track. The cantilever hoisting device is arranged below the steel fiber feeding system, and the upper end of the steel fiber feeding system is connected to the feeding port of the mixing station. The mixing station is a vertical axis planetary mixer station, including a 3m 3 3 vertical planetary mixers.

[0052] In conjunction with the accompanying drawings, the control method for the automated production line of coarse aggregate ultra-high performance concrete bridge deck in this embodiment includes the following steps:

[0053] S100, preparation before control: selecting a corresponding workstation layout diagram and processing technical parameter programming in the control center according to the type of bridge deck, and the main controller of the control center controls the production process according to the production plan and the selected program;

[0054] S200, raw material premixing zone control: prepare raw materials and fine powder, the main controller sends a signal to the sub-controller of the raw material premixing zone 1 to start each device, each raw material (not limited to sand and gravel) is dried by the drying system to reach the design parameters and then stored separately, and the measured raw materials are transported to the dry mixing host according to the raw material ratio for the first mixing, and cement is added for the second mixing to obtain a dry powder mixture, and the fine powder and the dry powder premix are sent to the mixing system 10 together by a feeding trolley, and water is added for the third mixing, and steel fiber is continued to be added for stirring to obtain a mixture;

[0055] The specific process of the above control is as follows: the control center sends a signal, the loader shovels the raw materials including but not limited to sand and gravel to the drying system for drying. After the drying reaches the design parameters, the dried raw materials are conveyed to the corresponding three-dimensional storage by the belt conveyor. The sand and gravel in the three-dimensional storage bin are measured by the three-level metering device and then transported to the dry mixing main machine. The feeding cart drives along the circular track to the receiving position of the dry mixing main machine to wait for dust-free receiving. Cement is added to the dry mixing main machine to obtain a dry powder mixture and unload it into the feeding cart. The feeding cart continues to drive to the core powder receiving station. The automatic feeding device of the core material distribution and batching system adds the dry powder into the feeding cart. The feeding cart circulates on the circular track. The feeding cart drives to the mixing system 10 of the mixing station for dust-free unloading, and steel fiber, additives, etc. are added for mixing. The mixing station uses two main machines for mixing, and the unloading is alternately circulated, while the feeding cart circulates on the track.

[0056] The specific feeding sequence of this embodiment is: the first mixing is premixing of coarse and fine aggregates for 1 minute, the second mixing is adding cement and the coarse and fine aggregates obtained from the first mixing for further premixing for 1 minute, all of which are carried out in the dry mixing main machine, the resulting dry powder mixture is received by the feeding trolley with the core fine powder material, and enters the mixing station together, and then liquid material and water are added for wet mixing for 3 minutes, and finally steel fiber is added for further wet mixing for 4 minutes, including the steel fiber input time of 2 minutes. From the drying, screening, and dust removal of raw materials to precise metering, high-efficiency mixing, and sufficient mixing of trace substances, the refined production of premixes is realized.

[0057] S300, steel frame forming area control: the main controller sends out a signal for mold assembly and steel frame mold entry, and completes the steel frame mold entry, i.e., the prefabricated board mold platform, before or at the same time as the mixed material is obtained;

[0058] S400, control of the mixture pouring area: the main controller pulls the precast panel formwork to the placing station according to the placing signal, and the sub-controller starts the placing system at the placing station to carry out a placing according to the placing path and sequence, sets the corresponding weight of the mixture and the placing speed required for the bridge deck type, controls the placing trolley to drive to the bottom of the mixing system 10 discharge port to receive the mixture, starts placing and leveling, and then the row array leveling integrated machine completes the first exhaust and leveling work, rests for a while, and controls the row vibrator and the flat plate vibrator and leveling machine to jointly vibrate and carry out the second exhaust and leveling work;

[0059] S500, product curing area control: the main controller sends out a curing signal, the shuttle bus will deliver the mold platform that has completed the previous process into the curing kiln, collect signals through the temperature and humidity sensors, and the sub-controller will control the steam heating system and the water spray system to perform curing work. The curing time in the kiln is 12h~36h, the curing temperature is 80~95℃, and the curing humidity is ≥90%. The shuttle bus will transfer the mold platform that has completed the previous process to the demolding station for demolding and cleaning. After demolding, the bridge panel will be hoisted to the water curing pool for immersion curing for 15~18 days, and a timed automatic drip irrigation curing device will be used for moisturizing curing.

[0060] After the coarse aggregate ultra-high performance concrete has been fully set and moisturized for 72 hours, demoulding can be carried out. After demoulding, it is hoisted into a water pool for 15 days of curing, and then transported to the storage area for moisturizing curing using a timed automatic drip irrigation curing device.

[0061] Preferably, the steel skeleton is installed and tied into the mold based on the end mold and the core mold in the prefabricated plate mold platform system, and the prefabricated steel cage is integrated with the end mold and the core mold so that it can be transported to the prefabricated mold platform as a whole. The prefabricated steel cage is formed by tying the longitudinal and transverse steel bars of the top steel mesh and the bottom steel mesh.

[0062] The prefabricated steel cage binding comprises the following steps:

[0063] S1 is equipped with two layers of steel mesh. First, the longitudinal steel bars of the bottom steel mesh are bolted and fixed to the tensioning reaction frame of the formwork. The tensioning force of a single steel bar is 8±0.5kN.

[0064] The S2 bottom layer of transverse reinforcement is tied with longitudinal reinforcement, and the tension of a single reinforcement is 10±0.5kN;

[0065] S3 The two ends of the transverse steel bars of the top steel mesh are bolted and fixed to the tensioning reaction frame of the formwork platform. The tensioning force of a single steel bar is 10±0.5kN;

[0066] The top layer of S4 longitudinal reinforcement relies on the transverse reinforcement binding, and the tensioning force of a single reinforcement is 8±0.5kN.

[0067] The longitudinal and transverse reinforcements must be connected by binding, and spot welding is not allowed; when removing the formwork, the transverse reinforcement should be released first, and then the longitudinal reinforcement. After the reinforcement is tensioned, the distance between the sleeve end and the adjacent side formwork should be 2 to 3 mm.

[0068] Preferably, the material distribution path and sequence are divided into n strips according to the pouring direction of the bridge deck. The first strip completes material distribution and leveling, and the row vibrator and the flat plate vibrator and leveler are started to jointly vibrate, exhaust, level and compact. The remaining strips are operated continuously in the order of the first strip distribution until the material distribution, leveling and exhaust and leveling work of all strips are completed. After the first exhaust and leveling work is completed and rested for a while, the mold platform is pulled as a whole to the exhaust and slurry lifting station for an exhaust and leveling work as a whole to complete the said first material distribution; wherein, the vibration frequency of the second exhaust and leveling work is greater than the vibration frequency of the first row leveling action = 200HZ.

[0069] The above-mentioned method of vibrating by combining a row vibrator and a flat plate vibrator and leveler can exhaust, level and compact the concrete immediately after spreading. In particular, by spreading the concrete in batches and vibrating after each spreading, bubbles in the concrete can be more effectively eliminated, and the density and strength of the concrete can be improved. In addition, the second exhaust and leveling work uses a higher vibration frequency, which further enhances the vibration effect and reduces the pores and defects inside the concrete.

[0070] Furthermore, the one-time cloth is completed for the n strips, wherein each strip is clothed twice, the weight of the first cloth accounts for 2 / 3 of the weight of each strip, and the second cloth accounts for 1 / 3 of the weight of each strip, and the overlap between two adjacent strips is 80 to 120 mm.

[0071] On the one hand, by dividing the pouring direction of the bridge deck into multiple strips for laying, the amount of laying in each area can be controlled more accurately, ensuring the uniformity of the laying of the entire bridge deck, which helps to reduce the difference in concrete strength and surface unevenness caused by uneven laying; on the other hand, the laying method of overlapping two adjacent strips by 80 to 120 mm helps to eliminate the seam marks between the strips and improve the overall flatness of the bridge deck surface. The flatness is not only beautiful, but also helps to improve the durability and performance of the bridge deck.

[0072] The entire material distribution and vibration process realizes continuous operation, reducing waiting time and manual intervention, thereby improving production efficiency. At the same time, the mold platform is pulled as a whole to the exhaust and slurry lifting station for overall exhaust and leveling work, which further shortens the production cycle.

[0073] In this embodiment, the design length of a single prefabricated bridge deck is 14.5m, the width of the bridge deck is 3.5m, the average thickness of the bridge deck is 0.18m, and the design calculation of the amount of concrete required for a single bridge deck is 9.1㎡. The one-time distribution process of a single prefabricated bridge deck is as follows: the mixture pouring area is divided into a distribution station and an exhaust slurry lifting station. The traction drive system has four tractors. First, the No. 1 tractor pulls the mold platform of the prefabricated bridge deck to be poured to the distribution station, and then switches to the No. 2 tractor after being pulled to the distribution station. The No. 1 tractor automatically returns to the starting position. A single prefabricated bridge deck of this specification needs to be fed 3 times by the mixing station. The average feeding time is 0.48㎡ / min, the spreading time is 180s / ㎡, and the average feeding time of the spreading system is 0.8㎡ / min. The spreading hopper is driven by the spreading trolley on the track of the walking frame and automatically goes to the discharging port of the mixing station to receive the material. After receiving the material, it is driven to the spreading station for spreading. The first strip starts to be spread, and the flattening machine on the lower side of the spreading system follows the flattening. Each strip is divided into two The weight of the first spreading is 2 / 3 of the total amount of concrete in the first strip, and the weight of the second spreading is 1 / 3 of the total amount of concrete in the first strip. The spreading trolley with the spreading hopper automatically returns to receive the material, and cooperates with the leveling machine to spread the material one grid at a time. The array leveling machine follows the spreading and leveling process to perform exhaust and leveling work. The width of the first to sixth strips is 2400mm, and the overlap between every two strips is 100mm. The first to sixth strips are laid according to the first strip. After the pouring, leveling, exhaust and leveling processes are completed in sequence, the material placing hopper is cleaned and the next material placing is awaited; tractor No. 2 is switched to tractor No. 3, which automatically returns to the starting position, and the formwork of the prefabricated bridge panel is towed by tractor No. 3 to the exhaust and slurry raising station for rest. After the rest is completed, tractor No. 3 moves forward to the exhaust and slurry raising station, where the row vibrator and the flat plate vibrator and leveler jointly vibrate the high-frequency exhaust and leveling work to complete one material placing. The time for completing the placing of a single prefabricated bridge panel is 30 minutes.

[0074] This embodiment is applied to the CA-RPC bridge deck production line of the Shiziyang project. Based on the integration of material characteristics and multi-equipment cross-operation of multi-process connections, combined with the bridge deck production tasks, it adopts automated and intelligent steel fiber feeding, concrete mixing, concrete pouring, and vibration equipment, connects each construction process in series in an assembly line manner, and arranges them reasonably to establish the first economical, reasonable, and efficient CA-RPC concrete bridge deck manufacturing production line.

[0075] It should be understood that the above-mentioned embodiments are one or more embodiments of the present invention, and there are many other embodiments and variations thereof based on the present invention; the variations and modifications made by ordinary technicians in this industry through the present invention without making pioneering innovations all fall within the scope of protection of the present invention.

Claims

1. An automated production line for coarse aggregate ultra-high performance concrete bridge deck, characterized in that: It includes raw material premixing area, steel frame forming area, mixture pouring area, product curing area and control center; The raw material premixing area is provided with a drying system, a three-dimensional storage system, a dry mix batching system, a core powder batching system and a stirring system in order of processing. The three-dimensional storage system includes a batching conveying system and a three-dimensional storage warehouse. The drying system is connected to the three-dimensional storage warehouse through a conveyor belt. A three-level metering device is provided under the three-dimensional storage warehouse to measure each raw material and send it to the dry mixing main machine of the dry mix batching system through the batching conveying system. The dry mix batching system, the core powder batching system and the stirring system are all connected through a feeding circulation system. The steel skeleton forming area includes a steel skeleton processing line, a prefabricated board formwork system and a traction drive system. Before or at the same time as the mixed material is obtained in the raw material premixing area, the steel skeleton processing line and the prefabricated board formwork system cooperate to complete the steel skeleton into the mold, and the formwork is pulled from the bottom of the mixing system to the material distribution station of the mixed material pouring area by the traction drive system; In the mixing material pouring area, a material distribution system, a row-array leveling integrated machine, a row-type vibrator and a flat plate vibrator and leveler are sequentially arranged along the length direction of the bridge deck. The material distribution system is arranged on the material distribution station. A leveler is arranged at the material discharging port of the material distribution system. The leveler automatically follows the material distribution system to perform horizontal leveling. The material distribution leveling process is closely followed by the exhaust and leveling process. The row-array leveling integrated machine completes the first exhaust and leveling process, and the mold platform is pulled to the exhaust and slurry raising station for resting first, and then the row-type vibrator and the flat plate vibrator and leveler jointly vibrate to perform the second exhaust and leveling process. The product curing area includes multiple independent curing kilns, each of which is equipped with a temperature and humidity sensor, a steam heating system and a water spray system, all of which are intelligently controlled by a control center. The mold platform enters the curing kiln through the shuttle bus of the overall ferry system. After curing, the mold platform is moved to the demolding station by the shuttle bus for demolding and cleaning.

2. The automated production line for coarse aggregate ultra-high performance concrete bridge deck according to claim 1, characterized in that: It also includes a human-machine interaction interface module. The control center is composed of four sub-controllers and a main controller that respectively control the raw material premixing area, the steel skeleton forming area, the mixture pouring area and the product curing area. The human-machine interaction interface module is connected to the main controller. The main controller performs overall scheduling and control of the production line, collects the working status information of the one or more sub-controllers, and combines the parameter information input by the human-machine interaction interface module, performs internal control logic analysis and database variable processing, and then outputs the generated overall status information of the production line to the human-machine interaction interface module for display, and at the same time sends control instructions to the one or four sub-controllers to control the equipment in the raw material premixing area, the steel skeleton forming area, the mixture pouring area and the product curing area on the production line separately or simultaneously.

3. The automated production line for coarse aggregate ultra-high performance concrete bridge deck according to claim 1, characterized in that: The feeding circulation system includes a circular track and a plurality of feeding trolleys. The circular track extends at the height of each discharge port of the dry mix batching system, the core powder batching system and the stirring system arranged in the raw material premixing area, and is enclosed to form a closed L-shaped circular structure. The circular track is evenly supported by a plurality of frame sections. A plurality of feeding trolleys are arranged on the circular track. The control center controls the feeding trolleys to move on the circular track to complete the delivery and reception of the dry mix batching system, the core powder batching system and the stirring system.

4. The automated production line for coarse aggregate ultra-high performance concrete bridge deck according to claim 1, characterized in that: The material distribution system includes a material distribution trolley, a material distribution hopper and a traveling frame with tracks. The traveling frame is set up on the material distribution station. The material distribution trolley automatically moves along the tracks on the traveling frame. The material distribution trolley is provided with an automatically flipping material distribution hopper, which is controlled by a control system to reach the discharge port below the mixing system to receive the material, as well as the movements of moving, unloading and returning.

5. The automated production line for coarse aggregate ultra-high performance concrete bridge deck according to claim 1, characterized in that: The mixture pouring area is provided with a constant temperature and humidity system, and the constant temperature and humidity system adopts an industrial air-conditioning system.

6. The automated production line for coarse aggregate ultra-high performance concrete bridge deck according to claim 1, characterized in that: The mixing system includes a mixing station, a cantilever hoisting device and a steel fiber feeding system. The dry powder mixture from the dry powder batching system is sent to the mixing station by a feeding trolley along the track. The cantilever hoisting device is arranged below the steel fiber feeding system, and the upper end of the steel fiber feeding system is connected to the feed port of the mixing station.

7. The control method for an automated production line for a coarse aggregate ultra-high performance concrete bridge deck according to any one of claims 1 to 6, characterized in that The following steps are involved: S100, preparation before control: selecting a corresponding workstation layout diagram and processing technical parameter programming in the control center according to the type of bridge deck, and the main controller of the control center controls the production process according to the production plan and the selected program; S200, raw material premixing zone control: prepare raw materials and fine powder materials, the main controller sends a signal to the raw material premixing zone sub-controller to start each device, each raw material is dried by the drying system to reach the design parameters and then stored separately, the measured raw materials are transported to the dry mixing host according to the raw material ratio for the first mixing, cement is added for the second mixing to obtain a dry powder mixture, the fine powder material and the dry powder premix are sent to the mixing system together by a feeding trolley, water is added for the third mixing, and steel fiber is continuously added for mixing to obtain a mixture; S300, steel frame forming area control: the main controller sends out a signal for mold assembly and steel frame mold entry, and completes the steel frame mold entry, i.e., the prefabricated board mold platform, before or at the same time as the mixed material is obtained; S400, control of the mixture pouring area: the main controller sends out a material distribution signal, pulls the precast panel formwork to the material distribution station, and the sub-controller starts the material distribution system at the material distribution station to carry out material distribution according to the material distribution path and sequence, sets the corresponding weight of the mixture and the distribution speed required for the bridge deck type, controls the material distribution trolley to drive to the bottom of the mixing system discharge port to receive the mixture, starts to distribute and level the mixture, and then the row-type leveling machine completes the first exhaust and leveling work, rests for a while, and controls the row-type vibrator and the flat plate vibrator and leveling machine to jointly vibrate and carry out the second exhaust and leveling work; S500, product curing area control: the main controller sends out a curing signal, the shuttle bus will deliver the mold platform that has completed the previous process into the curing kiln, collect signals through the temperature and humidity sensors, and the sub-controller will control the steam heating system and the water spray system to perform curing work. The curing time in the kiln is 12h~36h, the curing temperature is 80~95℃, and the curing humidity is ≥90%. The shuttle bus will transfer the mold platform that has completed the previous process to the demolding station for demolding and cleaning. After demolding, the bridge panel will be hoisted to the water curing pool for immersion curing for 15~18 days, and a timed automatic drip irrigation curing device will be used for moisturizing curing.

8. The control method for the automated production line of coarse aggregate ultra-high performance concrete bridge deck according to claim 7, characterized in that: The steel frame is installed and tied into the mold based on the end mold and core mold in the prefabricated plate mold system, and the prefabricated steel cage is integrated with the end mold and core mold. The prefabricated steel cage is formed by tying the longitudinal and transverse steel bars of the top steel mesh and the bottom steel mesh.

9. The control method for the automated production line of coarse aggregate ultra-high performance concrete bridge deck according to claim 7, characterized in that: The material distribution path and sequence are divided into n strips according to the pouring direction of the bridge deck. The first strip completes material distribution and leveling, and the row vibrator and the flat plate vibrator and leveler are started to jointly vibrate, exhaust, level and compact. The remaining strips are operated continuously in the order of the first strip distribution until the material distribution, leveling and exhaust and leveling work of all strips are completed. After the first exhaust and leveling work is completed and rested for a while, the mold platform is pulled as a whole to the exhaust and slurry lifting station for an exhaust and leveling work as a whole to complete the said first material distribution; wherein, the vibration frequency of the second exhaust and leveling work is greater than the vibration frequency of the first row and leveling action.

10. The control method for the automated production line of coarse aggregate ultra-high performance concrete bridge deck according to claim 9, characterized in that: The one-time cloth is to complete one-time cloth for the n strips, wherein each strip is clothed twice, the weight of the first cloth accounts for 2 / 3 of the weight of each strip, and the second cloth accounts for 1 / 3 of the weight of each strip, and the overlap between two adjacent strips is 80 to 120 mm.

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