Rotary concrete placing system for anchorages and pier foundation pits of super-large bridges

Abstract

This invention provides a rotary concrete placement system for deep foundation pits and anchorages of extra-large bridges, comprising a primary collection unit, a secondary collection unit, and a placement unit. The primary collection unit includes a wheeled hopper, a high-frequency vibrator, a chute, and a traction mechanism, positioned at a designated location on the edge of the foundation pit to transport concrete from concrete mixer trucks to the secondary collection unit. The secondary collection unit includes a central cylindrical support, a secondary collection hopper, an omnidirectional rotating mechanism, and a climbing mechanism, positioned at the center of the foundation pit to transport concrete from different directions and heights to the placement unit. The placement unit includes a placement rod, a first flexible joint, a second flexible joint, and a placement rod guide opening and closing mechanism to output concrete to the required pouring points. This system solves the problems of frequent equipment failures, high pouring costs, and unstable construction quality in concrete pouring equipment for deep foundation pits and anchorages of extra-large bridges.

Description

Technical Field

[0001] This invention relates to the field of construction technology for mega-bridges, and in particular to a rotating concrete placement system for deep foundation pits of anchorages and pier caps of mega-bridges. Background Technology

[0002] During the construction of mega-bridges, the task of pouring large volumes of concrete in deep foundation pits, such as anchorages and main pier caps, is crucial. Taking a certain Yangtze River bridge as an example, the concrete pouring volume for the main pier cap deep foundation pit was 8,000 m³, and the concrete pouring volume for the bottom sealing of the anchorage deep foundation pit alone was 30,000 m³. The pouring of large volumes of concrete in deep foundation pits places extremely stringent requirements on construction organization and mechanical stability.

[0003] Currently, the pouring of large-volume concrete in deep foundation pits is generally carried out using either overhead pumps or ground pumps. While these two methods differ in flexibility and pumping distance, both rely on equipment for pumping, resulting in high pouring costs. Regardless of whether it's overhead or ground pumping, the comprehensive cost of pumping one cubic meter of concrete is approximately 20 yuan. For a single pour of 10,000 m³ of large-volume concrete, the pumping cost alone can reach 200,000 yuan. This not only increases the total project cost but also places higher demands on the construction budget.

[0004] Furthermore, pumped concrete places extremely high demands on concrete performance, especially when pumping from top to bottom, which can easily lead to problems such as pipe blockage and bursting. Once these problems occur, the processing time is lengthy, not only affecting the construction schedule but also posing significant quality risks to the concrete pouring, and potentially even causing the failure of the entire project. Therefore, optimizing the construction plan, rationally arranging the pouring sequence, and exploring the use of new equipment such as rotary concrete placing booms can improve pouring efficiency and stability while reducing pumping costs. Summary of the Invention

[0005] The main objective of this invention is to provide a rotating concrete placement system for deep foundation pits and anchorages of extra-large bridges, which solves the problems of easy failure of concrete pouring equipment, high pouring cost, and unstable construction quality in deep foundation pits and anchorages of extra-large bridges.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a rotating concrete placement system for deep foundation pits of anchorages and pier caps of extra-large bridges, comprising a primary aggregate unit, a secondary aggregate unit and a placement unit;

[0007] The primary collection unit includes a wheeled collection hopper, a high-frequency vibrator, a chute, and a traction mechanism. The primary collection unit is set at a designated position on the edge of the foundation pit to collect the concrete from the concrete mixer truck and transport it to the secondary collection unit.

[0008] The secondary aggregate unit includes a central cylindrical upright, a secondary aggregate hopper, an omnidirectional rotating mechanism, and a climbing mechanism. The secondary aggregate unit is located at the center of the foundation pit and is used to collect the concrete material from the primary aggregate unit and transport it to the concrete placement unit from different directions and heights.

[0009] The concrete placement unit includes a concrete placement rod, a first flexible joint, a second flexible joint, and a concrete placement rod guide opening and closing mechanism. The concrete placement unit is connected to the secondary aggregate unit and is used to output concrete to the required pouring point.

[0010] In the preferred embodiment, in the primary collection unit, the bottom end of the side wall of the wheeled collection hopper box is provided with a discharge port, which is connected to a chute. The chute is connected to the central cylindrical upright through a traction mechanism. The traction mechanism includes a first wire rope and a first winch. The first winch is located at the top of the central cylindrical upright. One end of the first wire rope is connected to the end of the chute, and the other end is connected to the first winch. The first winch drives the end of the chute to rise and fall.

[0011] The wheeled hopper is equipped with rollers at the bottom for traction to a designated position, and a high-frequency vibrator is also provided on the side wall of the hopper to assist in material feeding.

[0012] In the preferred embodiment, the bottom end of the central cylindrical upright is welded or pre-embedded to the center of the bottom of the foundation pit, and the secondary collection hopper is sleeved on the middle of the central cylindrical upright through a sleeve. The upper end of the sleeve is provided with a climbing mechanism for driving the secondary collection hopper to move up and down along the central cylindrical upright.

[0013] The bottom of the secondary collection hopper is equipped with an omnidirectional rotation mechanism, and the first motor is located at the lower end of the sleeve to drive the secondary collection hopper to rotate around the central axis of the central cylindrical column.

[0014] In the preferred embodiment, the sleeve has a stepped surface in the middle, the rolling bearing is sleeved on the sleeve, its inner ring abuts against the stepped surface, the lower end of the secondary collection hopper is connected to the outer ring of the rolling bearing, a pressure cap is provided above the rolling bearing, the pressure cap is sleeved on the sleeve, its inner stepped surface abuts against the upper end of the outer ring of the rolling bearing, and its lower end is connected to the bottom of the inner surface of the secondary collection hopper.

[0015] In the preferred embodiment, racks are provided in the vertical grooves on both sides of the central cylindrical upright, and gear slots are provided on both sides of the upper end of the sleeve. The driving gear passes through the gear slots and meshes with the rack on one side, and the driven gear passes through the gear slots and meshes with the rack on one side. Both the driving gear and the driven gear are rotatably connected to the outer wall of the sleeve through bearing seats. The second motor is fixed at the upper end of the sleeve, and its output shaft is connected to the driving gear, driving the sleeve to move up and down along the central cylindrical upright.

[0016] In the preferred embodiment, the height of the rack does not exceed the outer surface of the central cylindrical upright, and the length of the rack is adapted to the depth of the foundation pit to be poured.

[0017] In the preferred embodiment, the lower surface of the secondary collection hopper is provided with an internal gear, and the outer surface of the lower end of the sleeve is fixed with a first motor. The output shaft of the first motor is connected to the power gear, and the power gear meshes with the internal gear to drive the secondary collection hopper to rotate around the central axis of the central cylindrical column.

[0018] In the preferred embodiment, the lower outer edge of the secondary collection hopper is provided with a discharge port, the upper end of the material distribution rod is connected to the discharge port through a first flexible joint, the lower end of the material distribution rod is provided with a second flexible joint, the middle part of the material distribution rod is connected to one end of a second steel wire rope through a ring, multiple rings are evenly provided on one side of the middle part of the outer surface of the secondary collection hopper, and a second winch is also provided below the secondary collection hopper. The other end of the second steel wire rope passes through multiple rings and is connected to the second winch, and the second winch drives the material distribution rod to rise and fall.

[0019] In the preferred embodiment, the drum end of the second winch extends a certain distance beyond the lower surface of the secondary collection hopper, the first motor and the second motor are located on the same side of the secondary collection hopper, and the second wire rope is arranged around the opposite semicircle of the motor mounting end.

[0020] In the preferred embodiment, an infrared ranging sensor and a control unit are also provided below the secondary aggregate hopper. The measuring surface of the infrared ranging sensor faces the bottom of the pit and is used to measure the distance between the secondary aggregate hopper and the concrete surface in the pit. The traction mechanism, omnidirectional rotation mechanism, climbing mechanism, material placing rod guide opening and closing mechanism, and infrared ranging sensor are all electrically connected to the control unit. The control unit is used to receive height information and transmit lifting commands.

[0021] Experimental measurements were conducted based on the properties of the concrete used in the construction, and corresponding "self-leveling boundaries" and "effective pouring height" were set.

[0022] The "self-leveling boundary" refers to the fact that, in most cases, the self-leveling height change curve of concrete can be fitted as a parabola. This is because during the flow of concrete, the flow velocity in the middle part is faster and the flow velocity in the edge part is slower, resulting in a higher height in the middle part and a lower height in the edge part. In other words, there is a boundary between the higher middle part and the slower-flowing edge part of the concrete over a period of time. This "self-leveling boundary" area is set as a unit of concrete pouring, and the "self-leveling boundary" value of the quality concrete can be obtained through experiments.

[0023] "Effective pouring height" refers to the maximum height that the concrete can effectively fill and maintain good performance during the single pouring process of the extra-large bridge in this application, due to its large height.

[0024] Infrared ranging sensors monitor the height undulation of the foundation pit plane to be poured, the height difference between the pit and the already poured concrete plane and the next point, and send the data to the control unit to specify the material placement plan. That is, based on the "self-leveling boundary", the distance between the center points of the two units to be poured is calculated, and the corresponding speed signal is sent to the omnidirectional rotating mechanism to drive the secondary aggregate hopper and the material placement unit to move to the next point at the corresponding speed to complete the material placement.

[0025] When the infrared ranging sensor detects that the height difference between adjacent points exceeds the "effective pouring height" or is more than 50% lower than the "effective pouring height," i.e. the height difference is too large or too small, the control unit calculates the required amount of concrete based on the difference data and sends a corresponding speed signal to the omnidirectional rotating mechanism. This controls the placing unit to slow down or increase its speed when flowing through the corresponding area, in order to obtain a larger or smaller pouring volume.

[0026] Infrared ranging sensors measure the height difference between the bottom of the secondary aggregate hopper and the pouring plane. The control unit obtains the height information of the climbing mechanism and the angle information of the guide opening and closing mechanism of the material placing rod, thereby knowing the spatial position of the material placing unit outlet, i.e., the second flexible joint, in the foundation pit. The control unit controls the second flexible joint at the end of the material placing rod to be as close as possible to the pouring surface, but not to directly contact it, for pouring.

[0027] The control unit obtains the height information of the climbing mechanism and controls the traction mechanism to lift the chute, so that the end of the chute is always close to the opening of the secondary collection hopper.

[0028] This invention provides a rotary concrete placement system for deep foundation pits of anchorages and pier caps of extra-large bridges, comprising a primary collection unit, a secondary collection unit, and a placement unit. The primary collection unit includes a wheeled collection hopper, a high-frequency vibrator, a chute, and a traction mechanism. The primary collection unit is located at a designated position on the edge of the foundation pit to collect concrete from concrete mixer trucks and transport it to the secondary collection unit. The secondary collection unit includes a central cylindrical support, a secondary collection hopper, an omnidirectional rotation mechanism, and a climbing mechanism. The secondary collection unit is located at the center of the foundation pit to collect concrete from the primary collection unit and transport it to the placement unit from different directions and heights. The placement unit includes a placement rod, a first flexible joint, a second flexible joint, and a placement rod guide opening and closing mechanism. The placement unit is connected to the secondary collection unit and is used to output concrete to the required pouring points.

[0029] Compared to overhead and ground pumps, which do not require a pumping system, have a stable structure, fewer pump pipe joints and are less prone to failure, are simple and easy to maintain, are relatively inexpensive, and can be used multiple times; they adopt a chute self-unloading method for concrete placement, which does not have high requirements for concrete performance, reduces the amount of admixtures and water, and ensures better concrete quality; automated and uniform concrete placement through sensors and control units ensures the efficiency and quality of the placement system. Attached Figure Description

[0030] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0031] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0032] Figure 2 This is a front view of the external structure of the secondary material collection unit and the material distribution unit of the present invention;

[0033] Figure 3 This is a top view of the external structure of the secondary material collection unit and the material distribution unit of the present invention;

[0034] Figure 4 This is a bottom view of the external structure of the secondary material collection unit and the material distribution unit of the present invention;

[0035] Figure 5 This is an isometric structural diagram of the secondary material collection unit and the material distribution unit in the explosion mode of the present invention;

[0036] Figure 6 This is a structural diagram of the connection between the secondary collection hopper and the central cylindrical upright of the present invention;

[0037] Figure 7 This is a cross-sectional axonometric structural diagram of the connection point of the climbing mechanism of the present invention;

[0038] Figure 8 This is a top view of the cross-sectional structure of the connection point of the climbing mechanism of the present invention;

[0039] Figure 9 This is an isometric structural diagram of the sleeve of the present invention;

[0040] Figure 10 This is a structural diagram showing the connection between the omnidirectional rotating mechanism and the secondary collecting hopper of the present invention;

[0041] Figure 11 This is a structural diagram showing the connection between the material distribution rod guide opening and closing mechanism, the secondary material collection hopper, and the material distribution rod of the present invention.

[0042] Figure 12 This is a structural diagram of the second winch of the present invention;

[0043] Figure 13 This is a flowchart of the control method of the present invention.

[0044] In the diagram: 1. Concrete mixer truck; 2. Wheeled hopper; 3. High-frequency vibrator; 4. Chute; 5. Traction mechanism; 501. First wire rope; 502. First winch; 6. Central cylindrical pole; 601. Rack; 7. Secondary hopper; 8. Omnidirectional rotating mechanism; 801. First motor; 802. Internal gear; 803. Power gear; 9. Climbing mechanism; 901. Drive gear; 902. Driven gear; 903. Bearing seat; 904. Second motor; 10. Placing boom; 11. First flexible joint; 12. Second flexible joint; 13. Placing boom guide opening and closing mechanism; 13. Second wire rope; 1301. Second winch; 1302. Sleeve; 14. Gear groove; 1401. Rolling bearing; 15. Pressure cover; 16. Infrared ranging sensor; 17. Control unit; 18. Detailed Implementation

[0045] Example 1

[0046] like Figures 1-13 As shown, a rotating concrete placement system for deep foundation pits of anchorages and pier caps of extra-large bridges includes a primary aggregate unit, a secondary aggregate unit, and a placement unit.

[0047] The primary collection unit includes a wheeled collection hopper 2, a high-frequency vibrator 3, a chute 4, and a traction mechanism 5. The primary collection unit is set at a designated position on the edge of the foundation pit to collect the material discharged from the concrete mixer truck 1 and transport it to the secondary collection unit.

[0048] The secondary aggregate unit includes a central cylindrical upright 6, a secondary aggregate hopper 7, an omnidirectional rotating mechanism 8, and a climbing mechanism 9. The secondary aggregate unit is located at the center of the foundation pit and is used to collect the concrete material from the primary aggregate unit and transport it to the concrete placement unit from different directions and heights.

[0049] The concrete placement unit includes a concrete placement rod 10, a first flexible joint 11, a second flexible joint 12, and a concrete placement rod guide opening and closing mechanism 13. The concrete placement unit is connected to the secondary aggregate unit and is used to output concrete to the required pouring point.

[0050] This application flexibly combines a self-balancing aggregate-chute system, a 360° rotatable secondary aggregate system, and an electrically openable and closeable placing unit. Each of these three systems performs its specific function, fully utilizing the kinetic energy of the concrete's own descent to complete the concrete pouring. The placing unit offers a wide coverage area and stable performance. Concrete is discharged from the concrete mixer truck 1 to the wheeled aggregate hopper 2 at the upper edge of the foundation pit, and then flexibly transferred via the chute 4 to the secondary aggregate hopper 7. From there, it is poured to the designated location by the placing unit. The secondary aggregate unit can rotate and lift, while the placing unit can open, close, and lift. Together, they control the concrete placement area to fully cover the interior of the foundation pit.

[0051] In the preferred embodiment, in the primary material collection unit, the bottom end of the side wall of the wheeled material collection hopper 2 is provided with a discharge port, which is connected to the chute 4. The chute 4 is connected to the central cylindrical pole 6 through a traction mechanism 5. The traction mechanism 5 includes a first wire rope 501 and a first winch 502. The first winch 502 is located at the top of the central cylindrical pole 6. One end of the first wire rope 501 is connected to the end of the chute 4, and the other end is connected to the first winch 502. The first winch 502 drives the end of the chute 4 to rise and fall.

[0052] The wheeled hopper 2 is equipped with rollers at the bottom for traction to a designated position, and a high-frequency vibrator 3 is also provided on the side wall of the hopper for assisting in material feeding.

[0053] The wheeled hopper 2 is designed as a box-type hopper with a length of 1.5 meters, a height of 1.5 meters, a width of 1 meter, and a volume of approximately 2 m³. The bottom of the hopper is equipped with rollers that can be pulled to a designated position as needed. The side of the hopper is designed with a discharge port and a chute connection. The bottom of the hopper is designed with a slope to facilitate material discharge. The wheeled hopper has its own counterweight, weighing approximately 5 tons when fully loaded. It is easy to move and has strong self-stability, which can counteract the bias pressure when discharging material from the chute. Concrete may cause blockage or slow flow at the discharge port. The high-frequency vibrator 3 vibrates the material in the wheeled hopper 2 evenly to solve the blockage problem.

[0054] The traction mechanism 5 is positioned above the highest point of the central cylindrical pole 6. The length of the chute 4 is adapted to the distance from the edge of the pit to the central cylindrical pole 6. As the secondary aggregate unit rises and falls, the traction mechanism 5 drives the end of the chute 4 to always be at a constant distance above the opening of the secondary aggregate hopper 7 to maintain the stability of the concrete delivery quality.

[0055] In the preferred embodiment, the bottom end of the central cylindrical upright 6 is welded or pre-embedded to the center of the bottom of the foundation pit, and the secondary collection hopper 7 is sleeved on the middle part of the central cylindrical upright 6 through the sleeve 14. The upper end of the sleeve 14 is provided with a climbing mechanism 9, which is used to drive the secondary collection hopper 7 to move up and down along the central cylindrical upright 6.

[0056] The bottom of the secondary collection hopper 7 is equipped with an omnidirectional rotation mechanism 8, and the first motor 801 is located at the lower end of the sleeve 14 to drive the secondary collection hopper 7 to rotate around the central axis of the central cylindrical upright 6.

[0057] The central cylindrical upright 6 is located at the center of the foundation pit. The bottom of the steel pipe is firmly welded or pre-embedded to the bottom of the foundation pit. The central cylindrical upright is the main load-bearing structural component. Its diameter is designed to adapt to the self-weight of the devices on it and the power support required for its drive, so as to meet the requirements of rigidity and anti-collapse. After pouring, the central cylindrical upright 6 is left as a pre-embedded part in the anchorage or pier.

[0058] By setting the sleeve 14, the installation and positioning requirements of the secondary collection hopper 7 are provided, and at the same time, an integrated installation space is provided for the power components of its required rotation and climbing mechanism, which facilitates the modular overall movement of the secondary collection unit.

[0059] In the preferred embodiment, the sleeve 14 has a stepped surface in the middle, the rolling bearing 15 is sleeved on the sleeve 14, and its inner ring abuts against the stepped surface. The lower end of the secondary collection hopper 7 is connected to the outer ring of the rolling bearing 15. A pressure cap 16 is provided above the rolling bearing 15. The pressure cap 16 is sleeved on the sleeve 14, and its inner stepped surface abuts against the upper end of the outer ring of the rolling bearing 15. Its lower end is connected to the bottom of the inner surface of the secondary collection hopper 7.

[0060] By setting the rolling bearing 15, the relative rotation between the secondary collection hopper 7 and the stepped surface of the sleeve 14 is avoided from direct contact. It can withstand a certain weight of the secondary collection hopper 7 and the load, significantly reducing the impact of friction and improving mechanical efficiency. The cover 16 fixes the rolling bearing 15 and provides a certain sealing effect between the sleeve 14 and the secondary collection hopper 7 to prevent concrete from leaking out from the joint gap.

[0061] In the preferred embodiment, racks 601 are provided in the vertical grooves on both sides of the central cylindrical upright 6, and gear grooves 1401 are provided on both sides of the upper end of the sleeve 14. The driving gear 901 passes through the gear groove 1401 and meshes with the rack 601 on one side, and the driven gear 902 passes through the gear groove 1401 and meshes with the rack 601 on one side. Both the driving gear 901 and the driven gear 902 are rotatably connected to the outer wall of the sleeve 14 through the bearing seat 903. The second motor 904 is fixed at the upper end of the sleeve 14, and its output shaft is connected to the driving gear 901, driving the sleeve 14 to move up and down along the central cylindrical upright 6.

[0062] In the preferred embodiment, the height of the rack 601 does not exceed the outer surface of the central cylindrical upright 6, and the length of the rack 601 is adapted to the depth of the foundation pit to be poured.

[0063] By setting symmetrical drive gear 901 and driven gear 902, the sleeve 14 is prevented from tilting to one side during the climbing process, thereby increasing the friction between it and the central cylindrical rod 6, which would hinder the climbing. The rack 601 is not higher than the outer surface of the central cylindrical rod 6, thus avoiding interference between the teeth of the rack 601 and the sleeve 14.

[0064] In the preferred embodiment, the lower surface of the secondary collection hopper 7 is provided with an internal gear 802, and the outer surface of the lower end of the sleeve 14 is fixed with a first motor 801. The output shaft of the first motor 801 is connected to a power gear 803, and the power gear 803 meshes with the internal gear 802 to drive the secondary collection hopper 7 to rotate around the central axis of the central cylindrical upright 6.

[0065] By setting the internal gear 802, the driving meshing surface is moved inward, reducing the impact of flying sand or concrete splashing on the rotational transmission at the pouring site. The first motor 801 and the secondary collection hopper 7 are integrated on the sleeve 14, and the rotation is controlled without interruption as the secondary collection hopper 7 is raised and lowered. The structure is simple, safe and reliable.

[0066] In the preferred embodiment, the lower outer edge of the secondary collection hopper 7 is provided with a discharge port, the upper end of the material distribution rod 10 is connected to the discharge port through a first flexible joint 11, the lower end of the material distribution rod 10 is provided with a second flexible joint 12, the middle part of the material distribution rod 10 is connected to one end of a second steel wire rope 1301 through a ring, a plurality of rings are evenly provided on one side of the middle part of the outer surface of the secondary collection hopper 7, and a second winch 1302 is also provided below the secondary collection hopper 7, the other end of the second steel wire rope 1301 passes through the plurality of rings and is connected to the second winch 1302, and the second winch 1302 drives the material distribution rod 10 to rise and fall.

[0067] The placing boom 10 is made of steel pipe with a diameter of 15cm and a wall thickness of more than 5mm to ensure smooth passage of large flow of concrete. The first flexible joint 11 ensures smooth material passage while allowing the placing boom 10 to move freely at the top. It can be made of rubber steel wire hose with a diameter of 15cm or rolled from waste rubber tires. The second flexible joint 12 uses the same material and size as the first flexible joint 11, increasing the flexibility of the end of the placing boom 10 and the coverage area of ​​the concrete.

[0068] The second winch 1302 drives its drum to rotate, causing the length of the second wire rope 1301 to change, so as to achieve lifting control of the fabric rod 10. The lifting point must be higher than the highest point of the fabric rod 10.

[0069] In the preferred embodiment, the drum end of the second winch 1302 extends a certain distance from the lower surface of the secondary collection hopper 7, the first motor 801 and the second motor 904 are located on the same side of the secondary collection hopper 7, and the second wire rope 1301 is arranged around the opposite semicircle of the motor mounting end.

[0070] The counterweights of the first motor 801 and the second motor 904 will cause the sleeve 14 to shift relative to the central cylindrical pole 6. By setting the winding surface of the second wire rope 1301 on the opposite side of the mechanical counterweight, the lifting load distribution of the cloth rod 10 is balanced with the mechanical counterweight, thus ensuring the stability of the overall structure.

[0071] In the preferred embodiment, an infrared ranging sensor 17 and a control unit 18 are also provided below the secondary aggregate hopper 7. The measuring surface of the infrared ranging sensor 17 faces the bottom of the pit and is used to measure the distance between the secondary aggregate hopper 7 and the concrete surface in the pit. The traction mechanism 5, the omnidirectional rotation mechanism 8, the climbing mechanism 9, the material placing rod guide opening and closing mechanism 13, and the infrared ranging sensor 17 are all electrically connected to the control unit 18. The control unit 18 is used to receive height information and transmit lifting commands.

[0072] Specifically, the method of using concrete self-weight placement does not have high requirements for concrete performance. The strength and quality of the concrete can be guaranteed by reducing parameters such as admixture dosage and water content. Experimental measurements are conducted based on the performance of the concrete used in construction, and corresponding "self-leveling boundaries" and "effective pouring height" are set.

[0073] The "self-leveling boundary" refers to the fact that, in most cases, the self-leveling height change curve of concrete can be fitted as a parabola. This is because during the flow of concrete, the flow velocity in the middle part is faster and the flow velocity in the edge part is slower, resulting in a higher height in the middle part and a lower height in the edge part. In other words, there is a boundary between the higher middle part and the slower-flowing edge part of the concrete over a period of time. This "self-leveling boundary" area is set as a unit of concrete pouring, and the "self-leveling boundary" value of the quality concrete can be obtained through experiments.

[0074] "Effective pouring height" refers to the maximum height that the concrete can effectively fill and maintain good performance during the single pouring process of the extra-large bridge in this application, due to its large height.

[0075] Infrared ranging sensor 17 monitors the height undulation of the foundation pit plane to be poured, the height difference between the already poured concrete plane and the next point, and sends it to control unit 18 to specify the material placement plan. That is, according to the "self-leveling boundary", the distance between the center points of the two units to be poured is calculated, and then the corresponding speed signal is sent to omnidirectional rotating mechanism 8 to drive the secondary collection hopper 7 and the material placement unit to move to the next point at the corresponding speed to complete the material placement.

[0076] When the infrared ranging sensor 17 detects that the height difference between adjacent points exceeds the "effective pouring height" or is more than 50% lower than the "effective pouring height", i.e. the height difference is too large or too small, the control unit 18 calculates the required amount of concrete based on the difference data and sends a corresponding speed signal to the omnidirectional rotating mechanism 8 to control the material placement unit to slow down or increase the speed when flowing through the corresponding area, so as to obtain a larger or smaller pouring volume.

[0077] Infrared ranging sensor 17 measures the height difference between the bottom surface of the secondary aggregate hopper 7 and the pouring plane. Control unit 18 obtains the height information of climbing mechanism 9 and the angle information of concrete placing rod guide opening and closing mechanism 13, thereby knowing the spatial position of the material placing unit outlet, i.e., the second flexible joint 12, in the foundation pit. Control unit 18 controls the second flexible joint 12 at the end of the concrete placing rod 10 to be as close as possible to the pouring surface, but not to directly contact it, so as to reduce the concrete quality decline caused by concrete segregation, improve pouring efficiency, and reduce air bubbles and voids.

[0078] The control unit 18 acquires the height information of the climbing mechanism 9 and controls the traction mechanism 5 to lift the chute 4, so that the end of the chute 4 is always close to the opening of the secondary aggregate hopper 7. This prevents the concrete from segregating due to excessive falling height during the process of being transported from the primary aggregate unit to the secondary aggregate unit. This would cause the coarse aggregate to separate from the mortar, resulting in a decrease in concrete quality and affecting the strength and durability of the final structure. Alternatively, it could cause splashing, thereby affecting the normal operation of the relevant mechanical equipment in the secondary aggregate unit.

[0079] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A rotating concrete placement system for deep foundation pits of anchorages and pier caps of extra-large bridges, characterized in that: It includes primary collection units, secondary collection units, and material distribution units; The primary collection unit includes a wheeled collection hopper (2), a high-frequency vibrator (3), a chute (4) and a traction mechanism (5). The primary collection unit is set at a designated position on the edge of the foundation pit to collect the material discharged from the concrete mixer truck (1) and transport it to the secondary collection unit. The secondary aggregate unit includes a central cylindrical upright (6), a secondary aggregate hopper (7), an omnidirectional rotating mechanism (8), and a climbing mechanism (9). The secondary aggregate unit is located at the center of the foundation pit and is used to collect the concrete material from the primary aggregate unit and transport it to the material placement unit from different directions and heights. The concrete placement unit includes a concrete placement rod (10), a first flexible joint (11), a second flexible joint (12), and a concrete placement rod guide opening and closing mechanism (13). The concrete placement unit is connected to the secondary aggregate unit and is used to output concrete to the pouring point. The bottom end of the central cylindrical pole (6) is welded or pre-embedded to the center of the bottom of the foundation pit. The secondary collection hopper (7) is sleeved on the middle part of the central cylindrical pole (6) through the sleeve (14). The upper end of the sleeve (14) is provided with a climbing mechanism (9) to drive the secondary collection hopper (7) to move up and down along the central cylindrical pole (6). The bottom of the secondary collection hopper (7) is equipped with an omnidirectional rotation mechanism (8), and the first motor (801) is located at the lower end of the sleeve (14) to drive the secondary collection hopper (7) to rotate around the central axis of the central cylindrical pole (6); The central cylindrical upright (6) has racks (601) in the vertical grooves on both sides, and the upper end of the sleeve (14) has gear grooves (1401) on both sides. The driving gear (901) passes through the gear groove (1401) and meshes with the rack (601) on one side. The driven gear (902) passes through the gear groove (1401) and meshes with the rack (601) on one side. The driving gear (901) and the driven gear (902) are rotatably connected to the outer wall of the sleeve (14) through the bearing seat (903). The second motor (904) is fixed on the upper end of the sleeve (14), and its output shaft is connected to the driving gear (901). The driven sleeve (14) moves up and down along the central cylindrical upright (6). The secondary collection hopper (7) has a discharge port on the lower outer edge. The upper end of the material distribution rod (10) is connected to the discharge port through the first flexible joint (11). The lower end of the material distribution rod (10) is provided with a second flexible joint (12). The middle part of the material distribution rod (10) is connected to one end of the second steel wire rope (1301) through a ring. Multiple rings are evenly distributed on one side of the middle part of the outer surface of the secondary collection hopper (7). A second winch (1302) is also provided below the secondary collection hopper (7). The other end of the second steel wire rope (1301) passes through multiple rings and is connected to the second winch (1302). The second winch (1302) drives the material distribution rod (10) to rise and fall. The drum end of the second winch (1302) extends a certain distance from the lower surface of the secondary collection hopper (7). The first motor (801) and the second motor (904) are set on the same side of the secondary collection hopper (7). The second wire rope (1301) is set around the opposite semicircle of the motor mounting end.

2. The rotary concrete placing system for deep foundation pits of anchorages and pier caps of extra-large bridges according to claim 1, characterized in that: In the first-level collection unit, the wheeled collection hopper (2) has a discharge port at the bottom of the side wall of the box. The discharge port is connected to the chute (4). The chute (4) is connected to the central cylindrical pole (6) through the traction mechanism (5). The traction mechanism (5) includes a first wire rope (501) and a first winch (502). The first winch (502) is located at the top of the central cylindrical pole (6). One end of the first wire rope (501) is connected to the end of the chute (4), and the other end is connected to the first winch (502). The first winch (502) drives the end of the chute (4) to rise and fall. The wheeled hopper (2) is equipped with rollers at the bottom for pulling to a designated position, and a high-frequency vibrator (3) is also provided on the side wall of the hopper for assisting in feeding.

3. The rotary concrete placing system for deep foundation pits of anchorages and pier caps of extra-large bridges according to claim 1, characterized in that: The sleeve (14) has a stepped surface in the middle. The rolling bearing (15) is sleeved on the sleeve (14), and its inner ring abuts against the stepped surface. The lower end of the secondary collection hopper (7) is connected to the outer ring of the rolling bearing (15). A pressure cap (16) is provided above the rolling bearing (15). The pressure cap (16) is sleeved on the sleeve (14), and its inner stepped surface abuts against the upper end of the outer ring of the rolling bearing (15). Its lower end is connected to the bottom of the inner surface of the secondary collection hopper (7).

4. The rotary concrete placement system for deep foundation pits of anchorages and pier caps of extra-large bridges according to claim 1, characterized in that: The height of the rack (601) does not exceed the outer surface of the central cylindrical upright (6), and the length of the rack (601) is adapted to the depth of the foundation pit to be poured.

5. The rotary concrete placing system for deep foundation pits of anchorages and pier caps of extra-large bridges according to claim 1, characterized in that: The lower surface of the secondary collection hopper (7) is provided with an internal gear (802), and the outer surface of the lower end of the sleeve (14) is fixed with a first motor (801). The output shaft of the first motor (801) is connected to the power gear (803). The power gear (803) meshes with the internal gear (802) to drive the secondary collection hopper (7) to rotate around the central axis of the central cylindrical pole (6).

6. The rotary concrete placing system for deep foundation pits of anchorages and pier caps of extra-large bridges according to claim 1, characterized in that: Below the secondary aggregate hopper (7) is an infrared ranging sensor (17) and a control unit (18). The measuring surface of the infrared ranging sensor (17) faces the bottom of the pit and is used to measure the distance between the secondary aggregate hopper (7) and the concrete surface in the pit. The traction mechanism (5), the omnidirectional rotation mechanism (8), the climbing mechanism (9), the material placing rod guide opening and closing mechanism (13), and the infrared ranging sensor (17) are all electrically connected to the control unit (18). The control unit (18) is used to receive height information and transmit lifting commands.

Images