Electrical control system of integrated upward moving formwork

Abstract

The invention provides an electrical control system of an integrated upward moving formwork. The control unit comprises a power distribution control module, a supporting leg control module, an outer mold hanging control module, a hanging basket jig frame control module, a crane carriage control module, a canopy control module, a vibration control module, a concrete distribution control module, a spraying maintenance control module and a tensioning control module. The control unit is controlled through a PLC. The informatization unit comprises a data acquisition terminal, an IoT wireless communication module, a monitoring cloud platform and a user terminal which are connected in sequence; the data acquisition terminal comprises a video monitoring module, a power supply monitoring module, a main beam assembly monitoring module, a supporting leg monitoring module, an outer mold hanging monitoring module, a hanging basket jig frame monitoring module, a crane carriage monitoring module, a canopy monitoring module, a vibration monitoring module, a concrete distribution monitoring module, a spraying maintenance monitoring module and a tensioning monitoring module. And the PLC is connected with the data acquisition terminal.

Description

Technical Field

[0001] The invention relates to the technical field of an upward movable mold frame, and in particular to an electrical control system of an integrated upward movable mold frame. Background Art

[0002] Bridges are an important part of high-speed rail lines, accounting for more than 50%. How to quickly make and erect beams is the key to ensuring the construction period. The upward mobile formwork is a construction machine that comes with its own formwork and uses abutments or piers as supports to cast bridges on site. It has been widely used in bridge construction. The upward mobile formwork has the characteristics of multiple control mechanisms, decentralized mechanisms and mobility. During the construction process, it has the disadvantages of low automation level, easy failure, high energy consumption and high operating costs. Therefore, it is necessary to develop an electrical control system with high automation and good safety. Summary of the invention

[0003] The present invention provides an electrical control system for an integrated upward movable mold frame, which realizes the control of various components of the upward movable mold frame and the collection and analysis of monitoring data through PLC control, and realizes the configuration and remote diagnosis of user monitoring terminals as well as monitoring data viewing, data analysis, report downloading, alarm reception, etc. by introducing Internet of Things technology, with high automation and good safety.

[0004] The technical solution adopted to achieve the above-mentioned purpose of the present invention is:

[0005] An electrical control system for an integrated upward mobile formwork frame includes a control unit and an information unit. The control unit includes a power distribution control module, a leg control module, an outer formwork hanging control module, a basket frame control module, a lifting trolley control module, a canopy control module, a vibration control module, a concrete distribution control module, a spray maintenance control module and a tensioning control module. Each control module of the control unit is controlled by a PLC and displayed and alarmed through a human-machine interface. The PLC is connected and communicated with the human-machine interface through Ethernet.

[0006] The information unit includes a data acquisition terminal, an IoT wireless communication module, a monitoring cloud platform and a user terminal connected in sequence from bottom to top, wherein the data acquisition terminal includes a video monitoring module, a power supply monitoring module, a main beam assembly monitoring module, an outrigger monitoring module, an external mold hanging monitoring module, a hanging basket tire frame monitoring module, a lifting trolley monitoring module, a canopy monitoring module, a vibration monitoring module, a concrete distribution monitoring module, a spray maintenance monitoring module and a tensioning monitoring module;

[0007] The PLC is connected to the data acquisition terminal to realize data transmission between the control unit and the information unit, and the PLC control information, fault diagnosis and warning information and monitoring information in the data acquisition terminal are transmitted to the monitoring cloud platform through the IoT wireless communication module. The monitoring cloud platform decodes the uploaded information through cloud computing and stores it in the database, performs data analysis, fault warning and remote graphic display on the health status of the equipment, and connects and communicates with the user monitoring terminal to realize remote monitoring, remote diagnosis and debugging, and key status reminders.

[0008] The power distribution control module supplies power to each sub-control system of the entire mobile mold frame. The power distribution control module is provided with short circuit, overload, overload, limit limit and leakage protection functions; the power distribution control module includes a main power cabinet and multiple distribution cabinets. The main power cabinet is responsible for the total power control of the entire mobile mold frame. The cabinet of the main power cabinet is provided with start, stop, emergency stop, indicator light and voltmeter function display. The operator performs power-on and power-off operations on the whole machine on the main power cabinet; the distribution cabinet is located at the front, middle and rear of the mobile mold frame; the power supply monitoring module collects data on the start and stop, voltage and power consumption of the power supply system, and uploads it to the monitoring cloud platform, so as to realize real-time viewing of the power supply status and power consumption of the equipment, and can export the historical data list for power consumption analysis.

[0009] The video monitoring module includes a monitoring cabinet and multiple cameras. The multiple cameras are distributed and installed on the upward mobile mold frame to carry out real-time monitoring of key working conditions such as equipment lifting, longitudinal movement through holes, opening and closing molds, awning extension and retraction, spray maintenance, and safety blind spots. The cameras are all connected to the monitoring cabinet, and the monitoring cabinet is connected to the IoT wireless communication module. The video information monitored by the camera is uploaded to the monitoring cloud platform, and remote monitoring is carried out through the user monitoring terminal.

[0010] The main beam assembly monitoring module includes monitoring of the disturbance deformation and stress of the main beam assembly;

[0011] The data acquisition terminal of the information unit also includes a beam monitoring module, which is connected to the monitoring cloud platform. The beam monitoring module includes temperature and humidity monitoring, strain monitoring and deflection deformation monitoring;

[0012] The deflection deformation monitoring of the main beam assembly and the beam body is achieved through a static level monitoring method, a photoelectric image displacement monitoring method, or a GNSS monitoring method.

[0013] The outrigger monitoring module includes pressure detection, stress detection, latch cylinder in-place detection and inclination detection. A pressure sensor is arranged at the hydraulic cylinder of each outrigger, a stress sensor is arranged at the column hinge of each outrigger, and an inclination sensor and a latch cylinder in-place detection sensor are arranged on each outrigger. The pressure sensor, stress sensor, inclination sensor and latch cylinder in-place detection sensor are all connected to the IoT wireless communication module, and the collected data is uploaded to the user monitoring terminal, so as to monitor the changes in the situation of each outrigger during the pouring and walking process, and control each outrigger according to the monitoring data;

[0014] The outrigger control module includes a control cabinet and a hydraulic system. Each outrigger is equipped with an independent control cabinet and hydraulic system. The operator can start and stop the pump station, and perform longitudinal movement, extension and retraction and flipping of the outriggers through the control cabinet panel or remote control. The front outrigger control cabinet and the middle outrigger control cabinet control the drive of the reducer, so that when the whole machine moves through the hole, each outrigger can move backwards by itself. When the whole machine moves through the hole, the pump stations of the front outrigger, the middle outrigger and the rear outrigger are controlled, so that the three outriggers are supported on the bridge and the piers with balanced force.

[0015] The basket tire frame monitoring module monitors the force of the basket tire frame, including stress sensors distributed on the tire frame suspension rods, and the data of the stress sensors are uploaded to the monitoring cloud platform;

[0016] The basket tyre frame control module performs hydraulic extension and retraction control on the tyre frame suspension rod, so that the basket tyre frame is suspended on the rear guide beam when passing through the hole, and the tyre frame is evenly stressed. The basket tyre frame is supported on the bridge when the steel cage is tied as a whole.

[0017] The outer mold hanging monitoring module monitors the stress change of the outer mold hanging and the synchronization of mold opening and closing;

[0018] The stress change monitoring of the external mold suspension is realized by the vibrating-wire strain gauge arranged on the C-type suspension. Eight vibrating-wire strain gauges are symmetrically arranged on the two C-type suspensions of each group of external mold suspensions. The eight vibrating-wire strain gauges are connected to an eight-channel vibrating-wire collector. The eight-channel vibrating-wire collector transmits the collected stress data to the monitoring cloud platform through 4G network communication, and further uploads it to the user monitoring terminal;

[0019] The synchronization monitoring of the opening and closing of the outer mold hanging is realized by a laser rangefinder. Baffles are installed on the two C-type hangings of each group of outer mold hangings. The baffles move horizontally on the cantilever beam assembly with the C-type hangings. A laser rangefinder is fixedly installed on the main beam facing the baffles. The laser rangefinder detects the real-time distance between the laser rangefinder and the baffles. The laser rangefinder is connected to the monitoring cloud platform to upload monitoring information.

[0020] The external mold hanging control module controls the opening and closing of the transverse cylinder mechanism and the support adjustment of the template support cylinder, and controls the synchronous opening and closing of the external mold hanging control module through the opening and closing synchronization monitoring data of the external mold hanging.

[0021] The crane trolley monitoring module collects the crane trolley's working status, descent depth, limit trigger, hoisting load, control interlock status, fault information, and provides real-time warning;

[0022] The hoisting trolley control module controls the lifting of the front and rear hoisting trolley winches and the trolley travel control. The power supply is pulley power supply, and the operation is wireless remote control + cabinet button. The cabinet is equipped with a wireless remote control and cabinet operation selection switch to control the movement of the hoisting trolley and the spreader. The hoisting motor and travel motor of the hoisting trolley are controlled by a frequency converter, which can be used for variable frequency speed regulation. Each frequency converter is equipped with a braking resistor to consume the energy generated by the descent of the mechanism. The lifting part is also equipped with overload alarm, height limit, low limit, and heavy hammer limit protection devices, and the travel part is provided with limit protection.

[0023] The canopy monitoring module is equipped with an intelligent weather station, which includes a temperature, humidity and pressure sensor, a wind sensor, and a rainfall sensor, which can monitor weather changes in real time and upload them to the cloud; the canopy monitoring module also includes a diffuse reflection infrared ranging sensor, which is set at the four corners of the canopy and detects whether there are obstacles in front of the moving position; the intelligent weather station and the diffuse reflection infrared ranging sensor are connected to the PLC to realize automatic adjustment of the canopy opening and closing according to the weather conditions and whether there are obstacles;

[0024] The canopy control module is equipped with a human-machine interface, which monitors the operating status of the equipment in real time and can adjust equipment parameters in real time according to construction requirements; when the automatic opening and closing function of the canopy is executed, the human-machine interface automatically sends a confirmation message to the administrator and executes it after confirmation; the human-machine interface monitors the equipment and fault detection in real time. When a fault occurs, it can be switched to manual assisted mode for normal operation.

[0025] The concrete distribution control module collects the working status information and operation time log information of the concrete distribution system through the IOT wireless communication module and uploads them to the monitoring cloud platform to make report statistics on the concrete distribution process; the concrete distribution control module is equipped with wired remote control and wireless remote control, and the switch quantity and electrical ratio are selected to make the operation of the concrete distribution boom more intelligent and convenient; the concrete distribution control module is equipped with an efficient hydraulic system, which makes the concrete distribution boom more maneuverable and flexible;

[0026] The vibration monitoring module collects the working status information and operation time log information of the vibration system through the IOT wireless communication module and uploads them to the cloud, and makes report statistics on the vibration process; the vibration control module is composed of a high-frequency attached vibrator and a vibration control cabinet. The high-frequency attached vibrators are installed at equal intervals on both sides of the outer template. The vibration control cabinet is connected to the high-frequency attached vibrator. The vibration control cabinet is equipped with a human-machine interface. The operator can set the continuous vibration time, interval time, and vibration times through the human-machine interface; at the same time, the human-machine interface monitors the operating status of the equipment in real time and issues real-time warnings; the circuit design of the vibration control cabinet has centralized start-up and time setting, and has overload and phase loss protection functions; the vibration control module is designed to be single-acting or group-linked according to needs, and is optionally operated with a wireless remote control to fully vibrate the deep part of the arch concrete, achieve full coverage of vibration in the circumferential, longitudinal and thickness directions, and effectively improve the strength and density of the concrete;

[0027] The spray maintenance monitoring module collects temperature, humidity and maintenance operation time log information through the IOT wireless communication module and uploads it to the cloud, so that equipment managers can monitor the maintenance status in real time; it also has three control modes: manual control by mobile phone APP, timed cycle, and automatic control by temperature and humidity sensing. With the video monitoring module, equipment maintenance management can be achieved without leaving home; after being turned on, it can realize timed and fixed-frequency spraying, and temperature and humidity detection spraying. The spray maintenance monitoring module is also equipped with a human-machine interface to monitor the operating status of the equipment in real time and adjust the maintenance parameters according to the construction parameter requirements in real time. The spray maintenance monitoring module is equipped with a complete self-diagnosis system and alarm system to implement real-time monitoring and fault detection of the equipment. When a fault occurs, it can be switched to manual assisted mode for normal operation; the spray maintenance control module is provided with a quick-plug connector to draw power from the distribution cabinet at the corresponding position, and the on and off of the circuit is controlled by the PLC to control the spray maintenance.

[0028] The tensioning monitoring module monitors the tensioning system through hydraulic sensors, displacement sensors and force sensors, collects the working status information of the tensioning system, cylinder pressure and displacement data, and operation time log information through the IOT wireless communication module, and makes report statistics on the tensioning process; the tensioning control module is equipped with an efficient hydraulic system to efficiently complete the tensioning work.

[0029] Compared with the prior art, the technical solution provided by the present invention has the following advantages: the electrical control system of the integrated upward movable formwork provided by the present invention realizes the control of each component of the upward movable formwork and the collection and analysis of monitoring data through PLC control, and realizes the configuration and remote diagnosis of the user monitoring terminal as well as monitoring data viewing, data analysis, report downloading, alarm reception, etc. by introducing the Internet of Things technology, thereby improving the quality of bridge construction and the safety of the entire set of equipment, with a high degree of automation and good safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a side view of the integrated upward movable mold frame of the present invention;

[0031] Figure 2 It is a top view of the integrated upward movable mold frame of the present invention;

[0032] Figure 3 is a side view of the front leg of the present invention;

[0033] Figure 4 It is a front view of the front leg of the present invention;

[0034] Figure 5 The front view of the front leg in the present invention when it is in the final stride position

[0035] Figure 6 A side view of the auxiliary legs of the present invention being lowered and retracted;

[0036] Figure 7 This is a front view of the auxiliary legs of the present invention when they are lowered;

[0037] Figure 8 It is a side view of the middle leg of the present invention;

[0038] Fig. 9 It is a front view of the middle leg in the present invention;

[0039] Fig.10 is a side view of the rear support leg of the present invention;

[0040] Fig.11 It is a front view of the rear supporting leg in the present invention;

[0041] Fig.12 It is a side view of the outer mold hanging assembly of the present invention;

[0042] Fig.13 It is a front view of the outer mold hanging assembly in the mold opening and through-hole state of the present invention;

[0043] Fig.14 It is a front view of the outer mold hanging assembly in the mold closing casting state in the present invention;

[0044] Fig.15 It is a side view of the tire frame assembly of the hanging basket in the present invention;

[0045] Fig.16 It is a front view of the tire frame assembly of the hanging basket in the present invention;

[0046] Fig.17 It is a side view of the overall hoisting assembly of the steel cage in the present invention;

[0047] Fig.18 It is a front view of the overall hoisting assembly of the steel cage in the present invention;

[0048] Fig.19 It is a top view of the overall hoisting assembly of the steel cage in the present invention;

[0049] Fig. 20 It is a front view of the overall hoisting assembly of the steel cage in the present invention when passing through the hole;

[0050] Fig.21 This is a side view of the installation of the electric hoist in the present invention;

[0051] Fig. 22 This is the installation front view of the electric hoist in the present invention;

[0052] Fig.23 It is a schematic diagram of the structure of the electric sliding awning in the present invention when it is in a retracted state;

[0053] Fig.24 It is a schematic diagram of the structure of the electric push-pull awning in the present invention when it is in the unfolded state;

[0054] Fig.25 It is a schematic diagram of the arrangement of the electric sliding awning in the present invention;

[0055] Fig.26 Schematic diagram of the arrangement of the spray head A and the spray head B in the spray curing assembly of the present invention, wherein (a) is a side view, (b) is a front view, and (c) is a top view;

[0056] Fig. 27 It is a schematic diagram of the arrangement of the spray head C in the spray curing assembly of the present invention, (b) is a main view;

[0057] Fig.28 Schematic diagram of the arrangement of the spray head D in the spray curing assembly of the present invention, (a) is a side view, (b) is a front view, and (c) is a top view;

[0058] Fig.29 The overall framework diagram of the electrical control system of the integrated upward movable mold frame provided by the present invention;

[0059] Fig.30 It is a partial framework diagram of the electrical control system in the present invention;

[0060] Fig.31 It is a schematic diagram of the arrangement of the machine equipment control unit on the integrated upward movable mold frame in the present invention;

[0061] Fig.32 Schematic diagram of the arrangement of the main beam assembly monitoring module in the present invention, wherein (a) is a side view and (b) is a front view;

[0062] Fig.33 The monitoring arrangement diagram of the front outrigger in the outrigger monitoring module of the present invention;

[0063] Fig.34 It is a stress monitoring arrangement diagram of the external mold hanging monitoring module in the present invention;

[0064] Fig.35 It is a layout diagram for monitoring the mold opening and closing synchronization of the outer mold hanging monitoring module in the present invention;

[0065] Fig.36 It is a connection schematic diagram of the tensioning system in the present invention;

[0066] Fig.37 The temperature and humidity monitoring arrangement diagram of the beam monitoring module of the present invention, wherein (a) is a side view and (b) is a front view;

[0067] Fig.38 The diagram is a deformation monitoring arrangement diagram of the beam monitoring module of the present invention, wherein (a) is a side view and (b) is a front view;

[0068] Fig.39 The stress monitoring arrangement diagram of the beam monitoring module of the present invention, wherein (a) is a side view and (b) is a front view;

[0069] In the figure: 101-bridge, 102-bridge pier, 103-external formwork, 1031-left external formwork, 1032-right external formwork, 104-inner formwork, 105-reinforcement cage;

[0070] 1-main beam assembly, 11-front guide beam, 12-main beam, 13-rear guide beam, 14-main cantilever beam, 15-auxiliary cantilever beam, 16-front outrigger running track, 17-front outrigger hanging wheel track, 18-hoisting track;

[0071] 21-front outrigger, 211-front outrigger running mechanism, 212-front outrigger upper crossbeam, 213-front outrigger column, 2131-front outrigger upper column, 2132-front outrigger lower column, 2133-split pin, 214-front outrigger lifting cylinder, 215-front outrigger lower crossbeam, 216-front outrigger transverse cylinder, 217-front outrigger transverse beam, 218-front outrigger fixed crossbeam, 219-front outrigger diagonal support cylinder;

[0072] 22- auxiliary outrigger, 221- auxiliary outrigger hinge seat, 222- auxiliary outrigger column, 223- auxiliary outrigger lifting cylinder, 224- auxiliary outrigger pad, 225- auxiliary outrigger rotating cylinder, 226- upper hinge seat, 227- lower hinge seat, 228- fine-tuning screw;

[0073] 23-middle outrigger, 231-C-type outrigger column, 232-middle outrigger lifting cylinder, 233-middle outrigger lower crossbeam, 234-middle outrigger running mechanism, 235-middle outrigger running track, 236-middle outrigger transverse cylinder, 237-middle outrigger pad, 238-support column;

[0074] 24-rear outrigger, 241-rear outrigger column, 242-rear outrigger lifting cylinder, 243-rear outrigger lower crossbeam, 244-rear outrigger running mechanism, 245-rear outrigger running track;

[0075] 3-external mold hanging assembly, 31-C type hanging, 32-C type hanging suspension rod, 33-formwork supporting cylinder;

[0076] 4-basket tire frame assembly, 41-basket tire frame, 411-bottom mold, 412-side mold tire frame, 413-inner mold tire frame, 42-tire frame hanging, 421-tire frame hanging rod, 422-diagonal support rod, 43-spiral column foot, 44-ladder platform;

[0077] 5-integral lifting assembly of steel cage, 51-lifting trolley, 52-hanging device, 521-hanging, 522-connecting longitudinal beam, 523-connecting cross beam, 524-cross beam, 525-cantilever cross beam, 526-longitudinal beam, 53-locking suspension rod, 54-auxiliary lifting tooling;

[0078] 6-electric hoist, 61-track beam, 62-beam running wheel set;

[0079] 71-Attached vibrator, 72-Electric push-pull canopy, 721-End beam motor, 722-Wind-resistant column, 73-Hydraulic concrete placing boom;

[0080] 8-spray maintenance assembly, 81-spray head A, 82-spray head B, 83-spray head C, 84-spray rack hanger, 85-spray rack, 86-spray head D, 87-water pipe, 88-water pump, 89-water tank;

[0081] 91-tensioning auxiliary tooling, 92-hydraulic station, 93-jack, 94-tool anchor, 95-high-pressure oil pipe, 96-signal line.

[0082] 2011-main power cabinet, 2012-front power distribution cabinet, 2013-middle power distribution cabinet, 2014-rear power distribution cabinet, 2021-front outrigger control cabinet, 2022-auxiliary outrigger control cabinet, 2023-middle outrigger control cabinet, 2024-rear outrigger control cabinet, 203-hoisting trolley control module, 204-canopy control module, 205-vibration control module, 206-concrete distribution control module, 207-spraying maintenance control module, 208-tensioning control module, 209-monitoring cabinet;

[0083] 301-static level, 3021-pressure sensor, 3022-stress sensor, 3023-tilt sensor, 3024-latch cylinder in-place detection sensor, 3031-vibrating string strain gauge, 3032-eight-channel vibrating string collector, 3033-laser rangefinder, 3034-baffle, 3041-temperature and humidity sensor, 3042-horizontal measuring point, 3043-reference point, 3044-strain measuring point. DETAILED DESCRIPTION

[0084] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments.

[0085] The electrical control system provided by the present invention is applied to an upward movable mold frame. Figure 1 As shown, it includes a main beam assembly 1, a leg assembly, an outer formwork hanging assembly 3, a hanging basket frame assembly 4, a steel cage integral hanging assembly 5, an electric hoist 6, an attached vibrator 71, an electric push-pull canopy 72, a concrete hydraulic placing boom 73, a spraying maintenance assembly 8, a tensioning auxiliary tooling 91 and other auxiliary facilities.

[0086] In this embodiment, the main beam assembly adopts a three-span structure, including a front guide beam 11, a main beam 12 and a rear guide beam 13 connected in sequence. Figure 1 and Figure 2 The main beam assembly adopts a double longitudinal beam structure, which has good lateral stability and strong wind resistance. The two outer sides of the main beam are symmetrically connected to multiple groups of main cantilever beams 14. In this embodiment, there are five groups of main cantilever beams. The main cantilever beams are a truss structure with a right-angle trapezoidal cross section. The main cantilever beams are fixed against the outer side of the main beam. Fig.13 The main cantilever beam is used for hanging the outer mold hanging assembly. The two outer sides of the rear guide beam are symmetrically connected to multiple groups of auxiliary cantilever beams 15. In this embodiment, six groups of auxiliary cantilever beams are provided. The auxiliary cantilever beam is a truss structure with a right-angled triangle cross section. A right-angled surface of the auxiliary cantilever beam is fixed against the outer side surface of the rear guide beam. Fig.16 , the auxiliary cantilever beam is used for hanging the basket tire frame assembly. In this embodiment, the front guide beam and the two longitudinal beams of the main beam are provided with front outrigger running tracks 16 on both sides of the bottom, the front guide beam and the two longitudinal beams of the main beam are provided with front outrigger hanging wheel tracks 17 on the bottom of the two outer sides (i.e. the outer sides of the two longitudinal beams), and the main beam and the rear guide beam are provided with hoisting tracks 18 for the running of the steel cage hoisting assembly. The rear guide beam is a truss structure with light weight, which reduces the support force on the bridge deck.

[0087] The leg assembly is installed at the bottom of the main beam assembly and supported on the bridge 101 and the pier 102, so that the entire main beam assembly is placed above the bridge deck. The leg assembly includes a front leg 21, an auxiliary leg 22, a middle leg 23 and a rear leg 24. The four legs are installed at the front end of the main beam, the middle of the main beam, the rear end of the main beam and the rear end of the rear guide beam in sequence.

[0088] Front outrigger structure Figure 3 and Figure 4 The front outrigger includes a front outrigger running mechanism 211, a front outrigger upper crossbeam 212, a front outrigger column 213, a front outrigger lifting cylinder 214, a front outrigger lower crossbeam 215, a front outrigger transverse cylinder 216, a front outrigger transverse beam 217 and a front outrigger fixed crossbeam 218. The front outrigger running mechanism includes a front supporting wheel group, a rear supporting wheel group, a hanging wheel group and a horizontal wheel group. The front outrigger running mechanism is driven by a reducer. The front outrigger running mechanism is connected to the front outrigger running track and the front outrigger hanging wheel track provided on the main beam assembly. The front outrigger running mechanism is driven by a reducer, so that the mobile formwork moves forward as a whole. During the through-hole operation, the initially tensioned beam body is not subjected to the heavy load of the bridge-building machine, so that the construction period requirements of rapid beam manufacturing are met. The upper roller assembly is fixed to the top of the upper crossbeam of the front leg, and the front leg column is fixed to the bottom of the upper crossbeam of the front leg. The front leg column includes an upper column 2131 of the front leg and a lower column 2132 of the front leg. The upper column of the front leg and the lower column of the front leg are connected by a pin shaft and a cotter pin 2133. When the front leg is in the last span, the lower column of the front leg can be disassembled to reduce the height of the front leg, which is suitable for the last span erection working condition, such as Figure 5 As shown. The front outrigger lifting cylinder passes through the front outrigger lower cross beam and is fixedly connected to the front outrigger lower cross beam. The two ends of the front outrigger lifting cylinder are respectively fixedly connected to the front outrigger column and the front outrigger transverse beam. The front outrigger lifting cylinder telescopes to adjust the height of the front outrigger. The front outrigger transverse beam is slidably connected to the front outrigger fixed cross beam. The two ends of the front outrigger transverse cylinder are respectively connected to the front outrigger transverse beam and the front outrigger fixed cross beam. The front outrigger transverse cylinder telescopes to drive the front outrigger transverse beam to move laterally along the front outrigger fixed cross beam. The front outrigger fixed cross beam is detachably anchored to the bridge pier through the front outrigger anchor rod. The front outrigger is an inverted triangle anti-overturning device. The upper edge of the front outrigger upper cross beam is longitudinally extended and connected to a support beam. The front outrigger diagonal support cylinder 219 is connected between the support beam and the front outrigger column.

[0089] The structure of the auxiliary legs is as follows Figure 6 and Figure 7As shown, it includes an auxiliary leg hinge seat 221, an auxiliary leg column 222, an auxiliary leg lifting cylinder 223, an auxiliary leg pad 224 and an auxiliary leg rotating cylinder 225, wherein the auxiliary leg column is connected to the bottom of the main beam through the auxiliary leg hinge seat, the auxiliary leg lifting cylinder is connected to the bottom of the auxiliary leg column, and the auxiliary leg pad is connected to the bottom of the auxiliary leg lifting cylinder through a fine-tuning screw 228. The two ends of the auxiliary leg rotating cylinder are respectively connected to the main beam and the auxiliary leg column through an upper hinge seat 226 and a lower hinge seat 227, and the auxiliary leg rotating cylinder is extended and retracted to drive the auxiliary leg to rotate around the main beam. During the through-hole process, the auxiliary leg lifting cylinder and the auxiliary leg rotating cylinder are controlled to extend so that the auxiliary leg is supported on the bridge beam surface; during the casting process, the integral steel cage needs to pass through the mold, at this time, the auxiliary leg lifting cylinder is controlled to shrink, and then the auxiliary leg rotating cylinder is controlled to shrink, so that the auxiliary leg is turned over and retracted to the bottom of the main beam.

[0090] The structure of the middle leg is as follows Figure 8 and Fig. 9 As shown, the middle leg is an O-shaped structure as a whole, which is convenient for the whole steel cage to pass through the mold. The middle leg includes a C-shaped leg column 231 symmetrically connected to both sides of the main beam, a middle leg lifting cylinder 232, a middle leg lower beam 233, a middle leg running mechanism 234, a middle leg running track 235, a middle leg transverse cylinder 236, a middle leg pad 237 and a supporting column 238. The C-shaped leg column is composed of multiple sections of columns connected by a pin shaft and a cotter pin, and the height is adjustable. The top of the C-shaped leg column is fixedly connected to the main beam, the middle leg lower beam is connected to the bottom of the two C-shaped leg columns, the middle leg running track is installed on the bridge beam surface, the middle leg running mechanism is installed at the bottom of the middle leg lower beam, and is installed on the middle leg running track, the middle leg running mechanism is a supporting wheel group, and the middle leg running mechanism is driven by a reducer to move the middle leg running mechanism along the middle leg running track. There are two middle outrigger lifting cylinders connected to the bottom of the lower crossbeam to control the lifting and lowering of the middle outrigger, thereby controlling the installation or detachment of the middle outrigger running mechanism from the middle outrigger running track; the middle outrigger pad is installed on the bridge beam surface, and the middle outrigger transverse cylinder is connected between the middle outrigger lower crossbeam and the middle outrigger pad. When the middle outrigger running mechanism is installed and detached from the middle outrigger running track, the middle outrigger transverse cylinder is extended and retracted to drive the middle outrigger to move laterally. The top of the support column can be rotatably hinged to the bottom of the main beam, and the bottom of the support column is detachably connected to the lower crossbeam of the middle outrigger ( Fig. 9The connection between the middle support column and the C-shaped support column has been removed, and the support column has been flipped to the bottom of the main beam). When the integral steel cage needs to pass through the mold, the support column flips to the bottom of the main beam to make room for the steel cage. When pouring concrete, the support column flips and supports between the main beam and the lower crossbeam of the middle support leg, and the middle support leg lifting cylinder is extended and retracted to support the middle support leg on the bridge. The flipping mechanism of the support column can be specifically referred to the auxiliary support leg. The front and middle legs of the mobile formwork can be moved horizontally by the cylinder, which is convenient for the mobile formwork to pass through small curves on the plane.

[0091] The structure of the rear legs is as follows Fig.10 and Fig.11 As shown, it includes a rear outrigger column 241, a rear outrigger lifting cylinder 242, a rear outrigger lower cross beam 243, a rear outrigger running mechanism 244 and a rear outrigger running track 245 connected in sequence. The rear outrigger column is fixedly connected to both sides of the rear guide beam, the rear outrigger running track is erected on the bridge beam surface, and the rear outrigger running mechanism is installed on the rear outrigger running track. Unlike the front outrigger and the middle outrigger, the rear outrigger running mechanism has no driving power. When the middle outrigger is running, it drives the rear outrigger running mechanism to run along the rear outrigger running track. Specifically, the rear outrigger running track is made of I-shaped steel. The outrigger assemblies cooperate with each other, so that during the construction of the mobile formwork and the through-hole process, there is no need to add embedded parts to the beam body and the pier body. Each outrigger is safely transported by itself, without auxiliary equipment, and has the ability to safely cross rivers. Each outrigger is hydraulically floated to ensure that when the three outriggers are supported, each outrigger can stably support the beam surface.

[0092] The structure of the outer mold hanging assembly is as follows Figure 12 to Figure 14As shown, it includes multiple groups of C-type hangers 31 distributed on the main beam, wherein the number of groups of C-type hangers corresponds to the number of groups of main cantilever beams. In this embodiment, the number of groups of C-type hangers is five, and each group of C-type hangers includes two C-type hangers, which are respectively installed on the main cantilever beam through a hydraulic transverse movement mechanism and are relatively opened and closed. The hydraulic transverse movement mechanism is a conventional technical means in the field and will not be described in detail here. In this embodiment, the outer formwork 103 is connected to the C-type suspension through a supporting assembly. The outer formwork is spliced ​​by a left outer formwork 1031 and a right outer formwork 1032. The left outer formwork and the right outer formwork are respectively connected to all left-side C-type suspensions and right-side C-type suspensions through a formwork supporting cylinder 33. The opening and closing of the C-type suspension drives the opening and closing of the left outer formwork and the right outer formwork. The formwork supporting cylinders are distributed on the outer formwork and the side and the bottom. The formwork supporting cylinders on the side of the outer formwork are hingedly connected to the outer formwork and the C-type suspension. After the left outer formwork and the right outer formwork are molded, the formwork supporting cylinders are used to adjust the posture of the left outer formwork and the right outer formwork and the beam elevation position to form a precise outer formwork space. In the mold-closing casting state, the C-type suspension is closed, and the bottoms of each group of two C-type suspensions are connected as a whole through connecting bolts, and the left outer formwork and the right outer formwork are connected as a whole. When the steel cage is put into the mold as a whole, the C-type suspension hanger 32 can be detachably connected between the main cantilever beam and the bottom of the C-type suspension to transfer the concrete load to the main beam. Moreover, the C-type suspension hanger is a through-cylinder tension hanger, which can quickly adjust the posture of the installed inner formwork. In the mold opening and through-hole state, the connection between each group of two C-type suspensions is released, the connection between the left outer formwork and the right outer formwork is released, and the C-type suspension hanger is removed to avoid affecting the overall mold entry of the steel cage.

[0093] The structure of the basket tire frame assembly is as follows Fig.15 and Fig.16As shown, the basket tire frame assembly is suspended and installed on the auxiliary cantilever beam, and is used to bind the steel cage 105 and the inner formwork 104 as a whole, wherein the inner formwork as a whole includes an end formwork and a prestressed steel pipe in addition to the inner formwork. The basket tire frame assembly includes a basket tire frame 41, multiple sets of tire frame suspensions 42 and a fixed support assembly. The structure of the basket tire frame is adapted to the structure of a section of a bridge box girder. The basket tire frame includes an inner mold tire frame 413, a bottom formwork 411 and a side mold tire frame 412 symmetrically connected to both sides of the bottom formwork. The side mold tire frame is made of a truss, and the inner mold tire frame is fixedly connected to the bottom formwork. Specifically, the inner mold tire frame is connected to the bottom formwork through a support beam, and the bottom of the support beam is fixedly connected to the bottom mold tire frame. The top of the support beam is connected to a longitudinal slideway, and the bottom of the inner mold tire frame is provided with an inner mold tire frame roller, and the inner mold tire frame roller is installed on the longitudinal slideway to facilitate the push-pull positioning and installation of the inner mold tire frame. The basket tire frame is hung under the rear guide beam through the tire frame hanging, and the basket tire frame is supported on the bridge beam surface through the fixed support assembly; the number of tire frame hanging groups is the same as the number of auxiliary cantilever beam groups, and each group of tire frame hanging includes two tire frame hangings connected to a group of auxiliary cantilever beams, and the tire frame hanging includes a tire frame hanging rod 421 and a diagonal support rod 422. The upper ends of each group of two tire frame hanging rods are hinged to the auxiliary cantilever beam, and the lower ends of each group of two tire frame hanging rods are respectively fixedly connected to the two side mold tire frames of the basket tire frame. The two ends of the diagonal support rod are respectively hinged to the auxiliary cantilever beam and the tire frame hanging rod. The tire frame hanging rod and the diagonal support rod are made of telescopic cylinders. The tire frame hanging rod and the diagonal support rod are telescopic to adjust the height of the basket tire frame. The fixed support assembly includes a plurality of spiral column feet 43 distributed on both sides of the bottom of the basket tire frame. The tops of the spiral column feet are locked and fixed to the basket tire frame by bolts, and the bottom of the spiral column feet is set as a triangular support base structure. When tying the steel cage and the inner formwork as a whole, the frame hanger rod and the diagonal brace rod are extended and retracted to support the spiral column foot on the bridge beam surface, and then the steel bars are tied; when passing through the hole, the frame hanger rod and the diagonal brace rod are extended and retracted to make the spiral column foot separate from the bridge beam surface, and the entire hanging basket frame assembly moves together with the main beam assembly. The hanging basket frame is connected to a ladder platform 44 for workers who tie the steel bars to enter the hanging basket frame.

[0094] The steel cage hoisting assembly is installed on the hoisting track of the main beam assembly. Its structure is as follows: Figure 17 to Figure 19As shown, the overall lifting assembly of the steel cage includes two lifting trolleys 51 and a sling 52. The two lifting trolleys are installed on the lifting track and move along the lifting track. The two lifting trolleys are respectively connected to the two ends of the top of the sling; the sling includes a lifting frame and a suspension 521 distributed and connected under the lifting frame. The suspension is integrally connected to the steel cage and the inner formwork. The overall steel cage and the inner formwork are lifted from the bottom of the rear guide beam to the outer formwork hanging assembly through the overall lifting assembly of the steel cage. Specifically, the hoisting frame includes connecting longitudinal beams 522, connecting cross beams 523, cross-linking beams 524, cantilever cross beams 525 and longitudinal connecting beams 526. There are two groups of connecting longitudinal beams and connecting cross beams. The two groups of connecting cross beams are respectively connected to the front and rear ends of the two groups of connecting longitudinal beams. The connecting cross beams are connected to the lifting trolley. The cross-linking beams are distributed and connected to the two groups of connecting longitudinal beams. There are two groups of longitudinal connecting beams. The two groups of longitudinal connecting beams are connected to the outer sides of the two groups of connecting longitudinal beams through cantilever cross beams. There are multiple groups of cantilever cross beams distributed between the longitudinal connecting beams and the connecting longitudinal beams. The cantilever cross beams are fixedly connected to the longitudinal connecting beams. The cantilever cross beams are hinged to the connecting longitudinal beams and connected with cotter pins. In order to avoid the C-type hanging boom, the cantilever cross beams and the longitudinal connecting beams can be flipped to the top of the hoisting frame (flipped 100°) for avoidance. Fig. 20 shown.

[0095] In order to facilitate the overall binding of the steel cage and the inner formwork, two electric hoists that can move vertically and horizontally are installed on the rear guide beam, such as Fig.21 and Fig. 22 As shown. The electric hoist is located behind the overall lifting assembly of the steel cage. The specification of the electric hoist is 5t. The electric hoist can flexibly take materials in the vertical and horizontal directions and transport them to the inside of the basket frame assembly to assist in the binding of the steel cage. Specifically, the electric hoist is installed on the rear guide beam through the track beam 61 and the beam running wheel group 62. The beam running wheel group is fixed on the track beam. The beam running wheel group is slidably connected to the rear guide beam and moves longitudinally along the rear guide beam. The electric hoist is installed on the track beam and moves laterally along the track beam.

[0096] In this embodiment, the attached vibrators are installed on both sides of the outer template. Figure 1 and Fig.13 , the vibration force is transmitted to the concrete through the external formwork, so that the overall molding quality of the concrete is better.

[0097] The electric push-pull canopy is installed above the main beam and the rear guide beam. It can provide shade, rain protection, and fold to prevent floating, preventing the outside weather from affecting the pouring of concrete and the binding of the steel cage, achieving all-weather construction, improving the overall working efficiency of the bridge construction machine, and ensuring the requirements of the total construction period. Each electric push-pull canopy is 36m long when unfolded, and 6-7m long when retracted. The structural diagram of the electric push-pull canopy when retracted and unfolded is shown below. Fig.23 and Fig.24As shown, the electric push-pull awning is driven to expand and retract by the end beam motor 721, and a wind-resistant column 722 is also provided at the fixed end of the electric push-pull awning. The H-shaped steel on the main beam is installed in reverse to prevent overturning. When there is a strong wind or typhoon warning, the electric push-pull awning should be bolted to the bolt connection point set on the main beam. In this embodiment, an electric push-pull awning is respectively provided at the rear end of the rear guide beam, the rear end of the main beam, and the front end of the main beam. The layout diagram of the electric push-pull awning is shown in FIG. Fig.25 shown.

[0098] There are two hydraulic concrete placing booms fixedly connected to the main beam. After the steel cage and the inner formwork are put into the mold as a whole, concrete is poured through the two hydraulic concrete placing booms. The hydraulic concrete placing booms are arranged at the front and rear ends of the main beam to meet the rapid placement construction needs of the entire pouring area.

[0099] The spray curing assembly includes the spray curing system for the formed box beam and the spray curing system for the cast-in-place beam surface. The spray curing system for the formed box beam includes the spray heads A81 distributed in the box beam holes, the spray heads B82 distributed on the beam surface, and the spray heads C83 located outside and below the box beam. Fig.26 and Fig. 27 As shown. The spray head C is connected to the bottom of the tire frame suspension through the spray frame hanger 84 and the spray frame 85. Specifically, the bottom of each set of tire frame suspension is connected to the spray frame hanger, and the bottom of the spray frame hanger is connected to the spray frame, and the spray frame is located outside and below the bridge box girder. The spray head C is distributed on the spray frame, so as to spray and maintain the formed bridge box girder; the cast-in-place beam surface spray maintenance system includes spray heads D86 distributed on both sides of the top of the outer formwork, as shown Fig.28 As shown, sprinkler head A, sprinkler head B, sprinkler head C and sprinkler head D are all connected to water pipe 87, and the water pipe is connected to water pump 88 and water tank 89, so as to perform spray maintenance on the cast-in-place beam surface.

[0100] The tensioning auxiliary tooling is installed on the front leg and the middle leg. Figure 1 and Figure 3 The mobile formwork is equipped with an intelligent tensioning system, which includes a hydraulic station 92 and a limit plate, an extension sleeve, a jack 93 and a tool anchor 94 installed on the prestressed steel bars in sequence. A high-pressure oil pipe 95 and a signal line 96 are connected between the jack and the hydraulic station. Fig.36 . The hydraulic station uses a high-performance radial piston pump, and the working oil pressure can be as high as 70MP; the applicable temperature range is -10℃~+45℃; the power supply voltage is 380V. The jack uses a special jack with an automatic tool anchor, which saves 50% of steel strands compared to traditional tensioning jacks. When the concrete strength of the beam reaches 80% of the design value, loosen the inner formwork, remove the end formwork, and then start the initial tensioning. After the concrete strength and elastic modulus of the beam reach the design value, the final tensioning is carried out when the age is not less than 7 days.

[0101] Based on the structure of the upward movable mold frame, the overall framework of the electrical control system provided in the present invention is as follows: Fig.29 As shown, it includes a control unit and an information unit.

[0102] The control unit includes a power distribution control module, an outrigger control module, an outer mold hanging control module (not shown in the figure), a basket frame control module (not shown in the figure), a lifting trolley control module 203, a canopy control module 204, a vibration control module 205, a concrete distribution control module 206, a spray curing control module 207 and a tensioning control module 208. The arrangement positions of each module on the mobile mold frame are as follows: Fig.31 As shown in the figure, the control unit has the characteristics of multiple control mechanisms, dispersed and movable mechanisms. Each control module of the control unit is controlled by Siemens S7-200smart series PLC and displayed and alarmed through the human-machine interface HMI (touch screen). PLC communicates with the human-machine interface through Ethernet. External signals are processed by PLC, which is safe and reliable. When a fault occurs, the PLC control system will automatically protect, the fault sound and light alarm will sound, and the touch screen will display the fault content. In order to ensure the safety of this machine, emergency stop buttons are set at various key parts of this machine. The emergency stop button can quickly cut off the power supply of the whole machine and perform an emergency stop.

[0103] The information unit includes data acquisition terminals, IoT wireless communication modules, monitoring cloud platforms and user terminals connected in sequence from bottom to top, such as Fig.30 As shown. The data acquisition terminal includes a video monitoring module, a power supply monitoring module, a main beam assembly monitoring module, an outrigger monitoring module, an external mold hanging monitoring module, a basket frame monitoring module, a lifting trolley monitoring module, a canopy monitoring module, a vibration monitoring module, a concrete distribution monitoring module, a spray maintenance monitoring module and a tension monitoring module. The PLC is connected to the data acquisition terminal to realize the data transmission between the control unit and the information unit. The IoT wireless communication module transmits the control information, fault diagnosis and warning information of the PLC and the monitoring information in the data acquisition terminal to the monitoring cloud platform through the Internet of Things technology. The monitoring cloud platform decodes the uploaded information through cloud computing and stores it in the database, performs data analysis, fault warning and remote graphic display of the equipment health status, and the monitoring cloud platform is connected and communicated with the user monitoring terminal to realize remote monitoring, remote diagnosis and debugging, and key status reminders.

[0104] User monitoring terminals include WEB monitoring terminals and APP monitoring terminals (which can be WeChat monitoring). Users can use WEB and APP to achieve remote monitoring, remote diagnosis and debugging, key status reminders, as well as monitoring data viewing, data analysis, report downloads, alarm reception, etc. The introduction of cloud technology can achieve remote monitoring, the information unit establishes a connection and communication with the PLC, collects equipment working data and fault information, and uploads them to the monitoring cloud platform for data processing and analysis. The system actively presents the results to the user to achieve risk early warning control of the equipment.

[0105] Specifically, the whole machine is powered by a generator, and the power supply adopts the TN-C mode (three-phase four-wire system) with a voltage level of 380V / 220V 50Hz AC. The generator is equipped with a set of power distribution control modules, which adopts a distributed power supply method to provide power to the crane trolley, each leg, intelligent canopy, spray maintenance assembly, concrete placing machine, information system and other auxiliary mechanisms, including the main drive motor power supply, control power supply, lighting power supply and maintenance power supply.

[0106] The power distribution control module includes a main power cabinet 2011 and multiple distribution cabinets. In this embodiment, the distribution cabinets include a front distribution cabinet 2012, a middle distribution cabinet 2013 and a rear distribution cabinet 2014 located at the front, middle and rear of the mobile mold frame, respectively. Fig.31 The power distribution control module is responsible for supplying power to each sub-control system of the entire mobile mold frame to ensure the normal operation of the equipment. The power distribution control module is equipped with protection functions such as short circuit, overload, overload, limit limit, and leakage. The power distribution cabinet of the frequently moving mechanism on the mobile mold frame is equipped with a quick-connect plug for easy and quick connection. The main power cabinet is responsible for the total power control of the entire mobile mold frame. The cabinet of the main power cabinet is equipped with function displays such as start, stop, emergency stop, indicator light, and voltmeter. The operator performs power-on and power-off operations on the main power cabinet.

[0107] The power supply monitoring module collects data on the start and stop, voltage, and power consumption of the power supply system, and uploads it to the monitoring cloud platform. Equipment managers can then view the power supply status and power consumption of the equipment in real time, and can also export historical data lists for power consumption analysis.

[0108] In this embodiment, the video monitoring module includes a monitoring cabinet 209 and multiple cameras, which are distributed and installed on the upward mobile mold frame. For example, cameras are installed at key locations such as the main beam assembly, the leg assembly, the steel cage integral hoisting assembly, the electric push-pull canopy and the spray maintenance assembly to monitor key working conditions such as equipment hoisting, longitudinal movement through holes, mold opening and closing, canopy extension and contraction, spray maintenance and other key working conditions and safety blind spots in real time. The cameras are connected to the monitoring cabinet, which is connected to the IoT wireless communication module. The video information monitored by the camera is uploaded to the monitoring cloud platform, and remote monitoring is performed through the user monitoring terminal, so that users can understand various operations in real time and intuitively on the WEB side and APP, and the information unit and the control unit interact with each other. The control module is controlled according to the video monitoring information to prevent interference between hoisting and other operations. The video monitoring module platform is internally constructed using strategies such as server clustering, load balancing, smooth capacity expansion on demand, and automatic fault recovery. The entire platform implements a variety of functions, including real-time multimedia data forwarding and management, mobile streaming media forwarding management, uninterrupted recording, video file retrieval and playback, video downloading, device status management, system alarm management, video transcoding, video on demand, etc. The entire platform is stable and reliable, safe to use, highly compatible, open interfaces, stackable services, multi-level cascading services, and smooth system expansion. Specifically, it includes: (1) video basic platform system management; (2) recording server; (3) video access server; (4) on-demand server; (5) alarm server; (6) GA / T 1400 view library server.

[0109] The main beam assembly monitoring module includes monitoring of the disturbance deformation and stress of the main beam assembly, wherein the disturbance deformation monitoring is realized by a static level monitoring method, an optoelectronic image displacement monitoring method, or a GNSS monitoring method.

[0110] The static level monitoring method monitors the deflection deformation of the main beam assembly through a settlement device arranged on the main beam assembly. The settlement device includes a single-chip microcomputer, a static level 301 and a liquid pipe. A plurality of static levels are provided and are respectively installed on a reference point and a measuring point. The reference point is located on a stable horizontal base point. The measuring points are symmetrically arranged on the double longitudinal beam structure of the main beam assembly. The same type of digital static levels are installed on the reference point and the measuring point. The liquid pipe connects all the static levels. Fig.32 As shown, when the measuring point rises or falls relative to the reference point, the pressure at each point will change. The static level monitors the pressure change and converts the pressure change into the relative settlement of each measuring point (the change of the vertical displacement of each measuring point relative to the reference point). The static level is connected to the single-chip microcomputer and transmits the monitored relative settlement to the single-chip microcomputer. The single-chip microcomputer stores the data and processes the data through the monitoring cloud platform and then transmits it to the remote user monitoring terminal.

[0111] The GNSS monitoring method is configured with a high-precision positioning base station, which is powered by solar energy. The high-precision positioning base station includes a GNSS antenna, a receiver, a power supply system and a communication system. Two GNSS antennas are installed on the cross-sections at both ends of the mobile mold frame, and the receiver is installed next to the GNSS antenna. The two GNSS antennas are connected to the receiver through feeders (i.e., antenna connection lines) for data transmission and power supply. The antenna Gaussian projection coordinates XYZ are connected to the CAN interface / or system platform to obtain the real-time position and plane posture of both ends of the mobile mold frame.

[0112] According to the stress measurement points of the main beam assembly during the construction process, stress sensors are used to monitor the stress of the main beam assembly structure during the construction process in real time. When using the stress sensor, the sensor is spot welded or riveted to the surface of the steel structure with screws, and the connection of the main beam assembly (i.e. the connection between the main beam, the front guide beam and the rear guide beam) is selected for stress monitoring.

[0113] The outrigger monitoring module includes pressure detection, stress detection, latch cylinder in-place detection and inclination detection. The front outrigger monitoring module is as follows: Fig.33 As shown. A pressure sensor 3021 is arranged at the hydraulic cylinder of each leg, a stress sensor 3022 is arranged at the hinge of the column of each leg, and an inclination sensor 3023 and a latch cylinder in place detection sensor 3024 are arranged on each leg. The pressure sensor, stress sensor, inclination sensor and latch cylinder in place detection sensor are all connected to the IoT wireless communication module, so that the collected data is transmitted to the monitoring cloud platform for processing, and further uploaded to the user monitoring terminal, so as to monitor the changes in the situation of each leg during the pouring and walking process, and control each leg according to the monitoring data. According to the on-site working conditions, the GIM500R inclination sensor and PBM4 pressure sensor that can adapt to harsh environments and are cost-effective are selected. The protection level of the GIM500R inclination sensor reaches IP69K, the detection accuracy is 0.1°, and the operating temperature range is -45-85℃. The operating temperature range of the PBM4 pressure sensor is -40-125℃, and the detection accuracy is ≤±0.5%FS (20℃), which fully meets the needs of this project.

[0114] The outrigger control module includes a front outrigger control cabinet 2021, an auxiliary outrigger control cabinet 2022, a middle outrigger control cabinet 2023 and a rear outrigger control cabinet 2024. Each outrigger control cabinet is provided with a quick-connect connector, which draws power from the power distribution cabinet at the corresponding position. Each outrigger is provided with an independent control cabinet and hydraulic system. The operator can realize the start and stop of the pump station, longitudinal movement, extension and retraction, and flipping of the outrigger through the control cabinet panel or the remote control. In addition, the front outrigger control cabinet and the middle outrigger control cabinet control the drive of the reducer so that each outrigger can reverse itself when the whole machine moves through the hole. Moreover, when the whole machine moves through the hole, the pump stations of the front outrigger, the middle outrigger and the rear outrigger are controlled so that the three outriggers are supported on the bridge and the piers with balanced force.

[0115] The external mold hanging monitoring module monitors the stress change of the external mold hanging and the synchronization of mold opening and closing. The stress change monitoring of the external mold hanging is realized by the vibrating wire strain gauge 3031 arranged on the C-type hanging. Fig.34 As shown, eight vibrating-wire strain gauges are symmetrically arranged on the two C-type suspensions of each set of outer mold suspensions, and the eight vibrating-wire strain gauges are connected to the eight-channel vibrating-wire collector 3032, and the eight-channel vibrating-wire collector is connected to the PLC control unit through a 4G network, so that the collected stress data is transmitted to the PLC control unit for processing, and further uploaded to the user monitoring terminal. The actual installation position of the vibrating-wire strain gauge is adjusted according to the finite element stress analysis results.

[0116] The opening and closing synchronization of the external mold hanging is monitored by the laser rangefinder 3033. Fig.35 As shown, baffles 3034 are installed on the two C-type hangers of each group of external mold hangers. The baffles move laterally on the cantilever beam assembly with the C-type hangers. A laser rangefinder is fixedly installed on the main beam toward the baffles. The laser rangefinder detects the real-time distance between the laser rangefinder and the baffles. The laser rangefinder is connected to the PLC control unit to transmit the real-time distance to the user monitoring terminal. The external mold hanger control module controls the opening and closing of the lateral cylinder mechanism and the support adjustment of the template support cylinder. The external mold hanger control module is connected to the PLC control unit. The PLC control unit receives the opening and closing synchronization monitoring of the external mold hanger and controls the external mold hanger control module to open and close the mold synchronously.

[0117] The basket frame monitoring module monitors the stress of the basket frame, including stress sensors distributed on the frame hanger rods. The stress data of the stress sensors are uploaded to the monitoring cloud platform through the IoT wireless communication module. The information unit and the control unit exchange information. The PLC controls each set of frame hangers to be evenly stressed according to the monitored stress data. The basket frame control module includes a basket frame control cabinet. The basket frame control cabinet controls the hydraulic extension and contraction of the frame hanger rods, so that the basket frame is suspended on the rear guide beam when passing through the hole, and the frame is evenly stressed. The basket frame is supported on the bridge when the steel cage is tied as a whole.

[0118] The trolley monitoring module collects information such as the trolley's working status (inverter current, voltage, frequency), descent depth, limit trigger, hoisting load, control interlock status, faults, etc., and issues real-time warnings. The trolley control module includes a trolley control cabinet, which controls the lifting of the front and rear trolley winches, the trolley's travel, and other related controls. The power supply method adopts pulley power supply, the control mode adopts PLC+touch screen, and the operation method adopts wireless remote control+buttons of this cabinet. The cabinet is equipped with a wireless remote control and a cabinet operation selection switch, which is convenient and fast to control the movement of the trolley and the hoisting equipment; the lifting motor and the travel motor of the trolley are controlled by inverters, and variable frequency speed regulation can be performed. Each inverter is equipped with a braking resistor to consume the energy generated by the descent of the mechanism. The lifting part is also equipped with overload alarm, height limit, low limit, heavy hammer limit and other protection devices, and the travel part is equipped with limit protection.

[0119] The canopy monitoring module is equipped with an intelligent weather station, which includes temperature, humidity and pressure sensors, wind sensors, and rainfall sensors, which can monitor weather changes (sunlight radiation, atmospheric temperature, humidity, wind speed and direction, etc.) in real time and upload them to the cloud; the canopy monitoring module also includes diffuse reflection infrared ranging sensors, which are set at the four corners of the canopy and detect whether there are obstacles in front of the moving position; the intelligent weather station and diffuse reflection infrared ranging sensors are connected to the PLC to realize automatic adjustment of the canopy opening and closing according to weather conditions and whether there are obstacles. For example, if the wind speed reaches level 6 or above, the canopy will automatically start to retract in order to avoid being blown over; if the solar radiation reaches a certain value, the canopy will automatically unfold.

[0120] The canopy control module is equipped with a human-machine interface, which monitors the operating status of the equipment in real time and can adjust the equipment parameters in real time according to construction requirements. When the automatic opening and closing function of the canopy is executed, the human-machine interface automatically sends a confirmation message to the administrator, and the operation is executed after confirmation. The human-machine interface monitors the equipment and fault detection in real time. When a fault occurs, it can be switched to manual assistance mode for normal operation.

[0121] The vibration monitoring module collects the working status information and operation time log information of the vibration system through the IOT wireless communication module and uploads it to the cloud, and reports and statistics the vibration process. The vibration control module consists of a high-frequency attached vibrator and a vibration control cabinet. According to the actual needs of the site, high-frequency attached vibrators are installed at equal intervals on both sides of the outer template. The vibration control cabinet is connected to the high-frequency attached vibrator. The vibration control cabinet is equipped with a human-machine interface. The operator can set the continuous vibration time, interval time, and vibration times through the human-machine interface; at the same time, the human-machine interface monitors the operating status of the equipment in real time and issues real-time warnings. The circuit design of the vibration control cabinet can realize centralized start-up and time setting, and has overload and phase loss protection functions. The vibration control module can be designed as a single action or group linkage according to needs, and can be operated with an optional wireless remote control to fully vibrate the deep part of the arch concrete, achieve full coverage of vibration in the circumferential, longitudinal and thickness directions, and effectively improve the strength and density of the concrete.

[0122] The concrete placing control module collects the working status information and operation time log information of the concrete placing system through the IOT wireless communication module and uploads it to the cloud to make reports and statistics on the concrete placing process. The concrete placing control module is equipped with wired remote control and wireless remote control. The switch quantity and electrical ratio are selected to make the operation of the concrete placing machine more intelligent and convenient. It is more convenient than rope pulling, which effectively improves the construction efficiency. The concrete placing control module is equipped with an efficient hydraulic system, which makes the placing machine more maneuverable and flexible, and can easily and efficiently complete the placing work.

[0123] The spray maintenance monitoring module collects temperature, humidity and maintenance operation time log information through the IOT wireless communication module and uploads it to the cloud. Equipment managers can monitor the maintenance status in real time. At the same time, it has three control modes: manual control by mobile phone APP, timed cycle, and automatic control of temperature and humidity sensing. With the video monitoring module, equipment maintenance management can be achieved without leaving home. After turning on, it can realize timed (fixed frequency) spraying and temperature and humidity detection spraying, that is, spray maintenance operations are automatically performed according to the set time and frequency. The spray maintenance monitoring module is also equipped with a human-machine interface to monitor the operating status of the equipment in real time. It can adjust the maintenance parameters in real time according to the construction parameter requirements, such as detecting the concrete temperature, ambient temperature and humidity, and automatically adjusting the maintenance water temperature according to the concrete temperature. The spray maintenance monitoring module is equipped with a complete self-diagnosis system and alarm system to implement real-time monitoring and fault detection of the equipment. When a fault occurs, it can switch to manual auxiliary mode for normal operation. The spray maintenance control module is equipped with a quick-plug connector, which takes power from the distribution cabinet at the corresponding position, and controls the on and off of the circuit through the PLC control unit, thereby controlling the spray maintenance.

[0124] The tensioning monitoring module monitors the tensioning system through hydraulic sensors, displacement sensors and force sensors. Specifically, the force sensor, displacement sensor and hydraulic sensor are installed on the jack of the tensioning system. The force sensor is a spoke-type sensor that directly measures force, and the force value is not affected by the friction and temperature of the jack. The displacement sensor is a wire (rod) type sensor, supported by a sliding guide rail, and the jack and the displacement contact adopt sliding contact, which solves the problem of the influence of the rotation of the jack piston on the displacement during tensioning. The IOT wireless communication module collects the working status information of the tensioning system, the cylinder pressure and displacement data, and the operation time log information, and generates reports and statistics for the tensioning process; the tensioning control module is equipped with an efficient hydraulic system to efficiently complete the tensioning work.

[0125] The data acquisition terminal of the information unit in this embodiment also includes a beam monitoring module, which includes temperature and humidity monitoring, strain monitoring and deflection deformation monitoring. The temperature and humidity monitoring is performed by a temperature and humidity sensor 3041 arranged at the web of the box beam in the middle of the main span. Fig.37 As shown, the temperature and humidity sensor is connected to the spray curing monitoring module to automatically adjust the curing water temperature according to the concrete temperature. The temperature and humidity sensor uses a 485 type collector arranged near it for data collection.

[0126] Deflection deformation monitoring is achieved through a static level monitoring method, a photoelectric image displacement monitoring method, or a GNSS monitoring method. The static level monitoring method sets horizontal measuring points 3042 at four deflection monitoring sections located at the middle of the main span, the quarter-point span, and the corresponding sections of one side of the bridge pier, and a reference point 3043 is set at the corresponding section of the pier on the other side of the bridge. The reference point and each measuring point are arranged at the same height as much as possible (at the web of the box girder). Each measuring point (reference point) contains one static level. A total of five static levels are arranged on the entire bridge, including one reference point static level. The specific measuring points are arranged as follows: Fig.38 As shown in the figure, five static level gauges use one 485 line, and a 485 type data acquisition instrument is used at the reference point for data acquisition.

[0127] The photoelectric image displacement monitoring method is monitored by a set of intelligent image processing and transmission monitoring systems. A reference point is set at the bottom of the pier on one side, and a measuring point is set at the bottom of the three sections corresponding to the middle of the main span and the quarter span. The intelligent image processing and transmission monitoring system is installed at the bottom of the pier on the other side of the bridge. The measuring point, the reference point and the intelligent image processing and transmission monitoring system are in a straight line. The intelligent image processing and transmission monitoring system collects displacement images, and the reference point is used to correct and compensate the data of the intelligent image processing and transmission monitoring system. The specific point layout can be adjusted according to the actual situation on site.

[0128] Four strain measuring points 3044 are arranged at the corresponding sections of the piers on both sides of the bridge and the mid-span section. The four strain measuring points are located at the top plate, bottom plate, and webs on both sides of the box girder, respectively. Fig.39 A vibrating-wire strain gauge is arranged at each strain measuring point, and the four vibrating-wire strain gauges at each section are collected using a 4-channel vibrating-wire collector; the data collected by the 4-channel vibrating-wire collector is processed by the IOT wireless communication module to the monitoring cloud platform, and further uploaded to the user monitoring terminal.

Claims

1. An electrical control system for an integrated upward movable mold frame, comprising a control unit and an information unit, characterized in that: The control unit includes a power distribution control module, an outrigger control module, an outer mold hanging control module, a basket frame control module, a lifting trolley control module, a canopy control module, a vibration control module, a concrete distribution control module, a spraying and curing control module, and a tensioning control module. Each control module of the control unit is controlled by a PLC and displayed and alarmed through a human-machine interface. The PLC is connected and communicated with the human-machine interface through Ethernet. The information unit includes a data acquisition terminal, an IoT wireless communication module, a monitoring cloud platform and a user terminal connected in sequence from bottom to top, wherein the data acquisition terminal includes a video monitoring module, a power supply monitoring module, a main beam assembly monitoring module, an outrigger monitoring module, an external mold hanging monitoring module, a hanging basket tire frame monitoring module, a lifting trolley monitoring module, a canopy monitoring module, a vibration monitoring module, a concrete distribution monitoring module, a spray maintenance monitoring module and a tensioning monitoring module; The PLC is connected to the data acquisition terminal to realize data transmission between the control unit and the information unit, and the PLC control information, fault diagnosis and warning information and monitoring information in the data acquisition terminal are transmitted to the monitoring cloud platform through the IoT wireless communication module. The monitoring cloud platform decodes the uploaded information through cloud computing and stores it in the database, performs data analysis, fault warning and remote graphic display on the health status of the equipment, and connects and communicates with the user monitoring terminal to realize remote monitoring, remote diagnosis and debugging, and key status reminders.

2. The electrical control system of the integrated upward movable mold frame according to claim 1 is characterized in that: The power distribution control module supplies power to each sub-control system of the entire mobile mold frame. The power distribution control module is provided with short circuit, overload, overload, limit limit and leakage protection functions; the power distribution control module includes a main power cabinet and multiple distribution cabinets. The main power cabinet is responsible for the total power control of the entire mobile mold frame. The cabinet of the main power cabinet is provided with start, stop, emergency stop, indicator light and voltmeter function display. The operator performs power-on and power-off operations on the whole machine on the main power cabinet; the distribution cabinet is located at the front, middle and rear of the mobile mold frame; the power supply monitoring module collects data on the start and stop, voltage and power consumption of the power supply system, and uploads it to the monitoring cloud platform, so as to realize real-time viewing of the power supply status and power consumption of the equipment, and can export the historical data list for power consumption analysis.

3. The electrical control system of the integrated upward movable mold frame according to claim 1 is characterized in that: The video monitoring module includes a monitoring cabinet and multiple cameras. The multiple cameras are distributed and installed on the upward mobile mold frame to carry out real-time monitoring of key working conditions such as equipment lifting, longitudinal movement through holes, opening and closing molds, awning extension and retraction, spray maintenance, and safety blind spots. The cameras are all connected to the monitoring cabinet, and the monitoring cabinet is connected to the IoT wireless communication module. The video information monitored by the camera is uploaded to the monitoring cloud platform, and remote monitoring is carried out through the user monitoring terminal.

4. The electrical control system of the integrated upward movable mold frame according to claim 1 is characterized in that: The main beam assembly monitoring module includes monitoring of the disturbance deformation and stress of the main beam assembly; The data acquisition terminal of the information unit also includes a beam monitoring module, which is connected to the monitoring cloud platform. The beam monitoring module includes temperature and humidity monitoring, strain monitoring and deflection deformation monitoring; The deflection deformation monitoring of the main beam assembly and the beam body is achieved through a static level monitoring method, an optoelectronic image displacement monitoring method, or a GNSS monitoring method.

5. The electrical control system of the integrated upward movable mold frame according to claim 1 is characterized in that: The outrigger monitoring module includes pressure detection, stress detection, latch cylinder in-place detection and inclination detection. A pressure sensor is arranged at the hydraulic cylinder of each outrigger, a stress sensor is arranged at the column hinge of each outrigger, and an inclination sensor and a latch cylinder in-place detection sensor are arranged on each outrigger. The pressure sensor, stress sensor, inclination sensor and latch cylinder in-place detection sensor are all connected to the IoT wireless communication module, and the collected data is uploaded to the user monitoring terminal, so as to monitor the changes in the situation of each outrigger during the pouring and walking process, and control each outrigger according to the monitoring data; The outrigger control module includes a control cabinet and a hydraulic system. Each outrigger is equipped with an independent control cabinet and hydraulic system. The operator can start and stop the pump station, and perform longitudinal movement, extension and retraction and flipping of the outriggers through the control cabinet panel or remote control. The front outrigger control cabinet and the middle outrigger control cabinet control the drive of the reducer, so that each outrigger can reverse itself when the whole machine moves through the hole. When the whole machine moves through the hole, the pump stations of the front outrigger, middle outrigger and rear outrigger are controlled so that the three outriggers are supported on the bridge and piers with balanced force; The basket tire frame monitoring module monitors the force of the basket tire frame, including stress sensors distributed on the tire frame suspension rods, and the data of the stress sensors are uploaded to the monitoring cloud platform; The basket tyre frame control module performs hydraulic extension and retraction control on the tyre frame suspension rod, so that the basket tyre frame is suspended on the rear guide beam when passing through the hole, and the tyre frame is evenly stressed. The basket tyre frame is supported on the bridge when the steel cage is tied as a whole.

6. The electrical control system of the integrated upward movable mold frame according to claim 1 is characterized in that: The outer mold hanging monitoring module monitors the stress change of the outer mold hanging and the synchronization of mold opening and closing; The stress change monitoring of the external mold suspension is realized by the vibrating-wire strain gauge arranged on the C-type suspension. Eight vibrating-wire strain gauges are symmetrically arranged on the two C-type suspensions of each group of external mold suspensions. The eight vibrating-wire strain gauges are connected to an eight-channel vibrating-wire collector. The eight-channel vibrating-wire collector transmits the collected stress data to the monitoring cloud platform through 4G network communication, and further uploads it to the user monitoring terminal; The synchronization monitoring of the opening and closing of the outer mold hanging is realized by a laser rangefinder. Baffles are installed on the two C-type hangings of each group of outer mold hangings. The baffles move horizontally on the cantilever beam assembly with the C-type hangings. A laser rangefinder is fixedly installed on the main beam facing the baffles. The laser rangefinder detects the real-time distance between the laser rangefinder and the baffles. The laser rangefinder is connected to the monitoring cloud platform to upload monitoring information. The external mold hanging control module controls the opening and closing of the transverse cylinder mechanism and the support adjustment of the template support cylinder, and controls the synchronous opening and closing of the external mold hanging control module through the opening and closing synchronization monitoring data of the external mold hanging.

7. The electrical control system of the integrated upward movable mold frame according to claim 1 is characterized in that: The crane trolley monitoring module collects the crane trolley's working status, descent depth, limit trigger, hoisting load, control interlock status, fault information, and provides real-time warning; The hoisting trolley control module controls the lifting of the front and rear hoisting trolley winches and the trolley travel control. The power supply is pulley power supply, and the operation is wireless remote control + cabinet button. The cabinet is equipped with a wireless remote control and cabinet operation selection switch to control the movement of the hoisting trolley and the spreader. The hoisting motor and travel motor of the hoisting trolley are controlled by a frequency converter, which can be used for variable frequency speed regulation. Each frequency converter is equipped with a braking resistor to consume the energy generated by the descent of the mechanism. The lifting part is also equipped with overload alarm, height limit, low limit, and heavy hammer limit protection devices, and the travel part is provided with limit protection.

8. The electrical control system of the integrated upward movable mold frame according to claim 1 is characterized in that: The canopy monitoring module is equipped with an intelligent weather station, which includes a temperature, humidity and pressure sensor, a wind sensor, and a rainfall sensor, which can monitor weather changes in real time and upload them to the cloud; the canopy monitoring module also includes a diffuse reflection infrared ranging sensor, which is set at the four corners of the canopy and detects whether there are obstacles in front of the moving position; the intelligent weather station and the diffuse reflection infrared ranging sensor are connected to the PLC to realize automatic adjustment of the canopy opening and closing according to the weather conditions and whether there are obstacles; The canopy control module is equipped with a human-machine interface to monitor the operating status of the equipment in real time and adjust the equipment parameters according to construction requirements in real time. When the automatic opening and closing function of the canopy is executed, the human-machine interface automatically sends a confirmation message to the administrator, and the function is executed after confirmation. The human-machine interface monitors equipment and detects faults in real time. When a fault occurs, it can be switched to manual assistance mode for normal operation.

9. The electrical control system of the integrated upward movable mold frame according to claim 1, characterized in that: The concrete distribution control module collects the working status information and operation time log information of the concrete distribution system through the IOT wireless communication module and uploads them to the monitoring cloud platform to make report statistics on the concrete distribution process; The concrete placing control module is equipped with wired remote control and wireless remote control. The switch quantity and electrical ratio are selected to make the operation of the concrete placing machine more intelligent and convenient. The concrete placing control module is equipped with an efficient hydraulic system, which makes the concrete placing boom more maneuverable and flexible. The vibration monitoring module collects the working status information and operation time log information of the vibration system through the IOT wireless communication module and uploads them to the cloud, and makes report statistics on the vibration process; the vibration control module is composed of a high-frequency attached vibrator and a vibration control cabinet. The high-frequency attached vibrators are installed at equal intervals on both sides of the outer template. The vibration control cabinet is connected to the high-frequency attached vibrator. The vibration control cabinet is equipped with a human-machine interface, and the operator can set the continuous vibration time, interval time, and vibration number through the human-machine interface; at the same time, the human-machine interface monitors the operating status of the equipment in real time and issues real-time warnings; the circuit design of the vibration control cabinet has centralized startup and time setting, and has overload and phase loss protection functions; The vibration control module is designed as single action or group linkage according to the needs, and can be operated with an optional wireless remote control to fully vibrate the deep part of the arch concrete, achieving full coverage of vibration in the circumferential, longitudinal and thickness directions, effectively improving the strength and density of the concrete; The spray maintenance monitoring module collects temperature, humidity and maintenance operation time log information through the IOT wireless communication module and uploads it to the cloud, so that equipment managers can monitor the maintenance status in real time; it also has three control modes: manual control by mobile phone APP, timed cycle, and automatic control by temperature and humidity sensing. With the video monitoring module, equipment maintenance management can be achieved without leaving home; after being turned on, it can realize timed and fixed spraying, temperature and humidity detection spraying. The spray maintenance monitoring module is also equipped with a human-machine interface to monitor the operating status of the equipment in real time, and adjust the maintenance parameters in real time according to the construction parameter requirements. The spray maintenance monitoring module is equipped with a complete self-diagnosis system and alarm system to implement real-time monitoring and fault detection of the equipment. When a fault occurs, it can be switched to manual auxiliary mode for normal operation; The spray maintenance control module is equipped with a quick-plug connector, which draws power from the power distribution cabinet at the corresponding position and controls the on and off of the circuit through the PLC, thereby controlling the spray maintenance.

10. The electrical control system of the integrated upward movable mold frame according to claim 1, characterized in that: The tension monitoring module monitors the tension system through hydraulic sensors, displacement sensors and force sensors, collects the tension system working status information, cylinder pressure and displacement data, operation time log information through the IOT wireless communication module, and performs report statistics on the tension process; The tensioning control module is equipped with an efficient hydraulic system to efficiently complete the tensioning work.

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