Automatic T-beam prefabrication production method and system

Abstract

The invention discloses a production method for automatically prefabricating a T-shaped beam, which is characterized by comprising the following steps of: (1) prefabricating a T-shaped beam; the method comprises the following steps: positioning a movable pedestal, manufacturing and mounting a web steel bar, integrally hoisting the web steel bar into a mold, closing a hydraulic template, manufacturing and mounting a top plate steel bar, integrally hoisting the top plate steel bar into the mold, mixing and transporting T-beam concrete, pouring the T-beam concrete, demolding the T-beam and moving the T-beam to an intelligent steam-curing chamber, generating steam by a combustion boiler, intelligently steam-curing the T-beam, moving the T-beam to an intelligent tensioning area, and tensioning the T-beam. And anchor sealing and grouting are conducted. An automatic T-beam prefabricating system comprises a reinforcing steel bar machining and mounting center, a concrete pouring center, a T-beam curing center, a T-beam tensioning and grouting center and a beam yard intelligent monitoring center, and is characterized in that the reinforcing steel bar machining and mounting center, the concrete pouring center, the T-beam curing center and the T-beam tensioning and grouting center are connected with the beam yard intelligent monitoring center. The production period is short, the speed is high, and the maintained T-beam is uniform in color and luster and good in quality.

Description

Technical Field

[0001] The invention belongs to the technical field of bridges, and in particular relates to a production method for automatic T-beam prefabrication, and also relates to the system. Background Art

[0002] T-beam refers to a beam with a T-shaped cross section. The protruding parts on both sides are called flanges, and the middle part is called beam ribs. It is formed by digging out the concrete in the tensile zone of the rectangular beam that does not play a role in the bending strength. In addition to having the same bending strength as the original rectangular beam, it can save concrete, reduce the deadweight of the component, and improve the spanning capacity; prefabricated beams can be processed in the factory and then transported to the designated construction site for assembly, so it can effectively shorten the construction period. Due to its many excellent characteristics, T-beams are widely used in current road and bridge construction. In the T-beam prefabrication production process in the prior art, the steel bars are tied and installed in the concrete pouring center using a fixed membrane or a traditional membrane, resulting in low efficiency and long time; the concrete is cured by natural curing or watering, and small and micro steam curing is used in winter, resulting in a long curing time (generally 7 days). Natural curing or normal temperature curing is used, and the quality of the cured T-beam is unstable due to the different temperatures during the day and night and in different seasons. Summary of the invention

[0003] The purpose of the present invention is to overcome the above disadvantages and provide an automated T-beam prefabrication production method with a short production cycle, high speed, stable quality of the cured T-beam and good appearance.

[0004] The purpose of the present invention and the solution of its main technical problems are achieved by adopting the following technical solutions: An automated T-beam prefabrication production method of the present invention is characterized by comprising the following steps: 1) Positioning of the mobile pedestal: hoist the mobile pedestal onto the track in the concrete pouring area for positioning; 2) Fabrication and installation of web reinforcement: tying and installing reinforcement on the frame of the reinforcement processing center; 3) Lifting the web reinforcement into the formwork as a whole: transport the tied reinforcement cage as a whole to the concrete pouring center, and use a gantry crane to lift the web reinforcement cage as a whole into the formwork; 4) Hydraulic template closing: Use intelligent hydraulic template system to close the template; 5) Fabrication and installation of top plate reinforcement: Tie the top plate reinforcement on the frame of the reinforcement processing center, transport it to the concrete pouring center and wait for hoisting into the mold; 6) Lift the top plate reinforcement into the formwork as a whole: lift the top plate reinforcement into the formwork as a whole; 7) T-beam concrete mixing and transportation: After the concrete mixing is completed, it is transported to the concrete pouring center by transportation equipment; 8) T-beam concrete pouring: Use a tablet computer to control the attached vibrator and the vibrating rod to pour concrete in the T-beam formwork with one-button intelligent instant opening and closing; 9) T-beam demoulding and moving to the intelligent steam curing room: After the concrete reaches the demoulding conditions, the side and end forms are removed with one click, and the beam is moved to the steam curing shed of the T-beam curing center for curing through the mobile pedestal; 10) Combustion boiler to generate steam: Environmentally friendly biomass pellets are burned in the boiler room to generate steam, and the steam is transported to the steaming shed through pipelines; 11) Intelligent steam curing of T-beams: The intelligent steam curing system is used to perform constant temperature and humidity curing according to the set temperature and humidity curve; 12) Move the T-beam to the intelligent tensioning area: After steaming and curing, move the beam to the tensioning and grouting center; 13) Tensioning: Intelligent tensioning equipment is used to achieve precise tensioning of prestressed tendons through computer control technology; 14) Anchor sealing: After tensioning is completed, the anchor sealing operation is carried out; 15) Grouting: Grouting is performed on the prestressed holes to ensure the durability of the structure; 16) Hoisting to beam storage area / erection: Finally, the prefabricated T-beams are hoisted to the beam storage area or construction site for erection.

[0005] The one-button intelligent instant opening and closing T-beam formwork described in step 8) includes a lifting cylinder, a guide sleeve, a support screw, a slope-adjusting cylinder, a formwork, a slope-adjusting formwork, a mobile pedestal, a track, a two-stage cylinder, and a base, and is characterized in that a lifting cylinder, a guide sleeve, and a two-stage cylinder are respectively installed on the base, and the lifting cylinder, the guide sleeve, and the two-stage cylinder are respectively connected to the lower end of the formwork, and a support screw, a slope-adjusting cylinder, and a slope-adjusting formwork are respectively installed on the upper end of the formwork, and the support screw and the slope-adjusting cylinder are respectively connected to the slope-adjusting formwork, and a mobile pedestal is installed at the lower end of the formwork, and the mobile pedestal is installed on the track.

[0006] The mobile platform includes a top plate, a cross beam, a longitudinal beam, a connecting seat, a running wheel seat, a running wheel, a bottom plate, and an anti-falling device, and is characterized in that a running wheel insertion shaft is placed in the running wheel seat, the running wheel is placed on the track, the running wheel seat is connected to the bottom plate by bolts, the bottom plate is connected to the longitudinal beam by bolts, the cross beam is fixedly installed on the longitudinal beam, the top plate is installed on the cross beam, the connecting seat is fixedly installed on the side of the longitudinal beam, and the anti-falling device is installed on the connecting seat.

[0007] Step 10) The steaming shed is a closed steaming shed.

[0008] An automated T-beam prefabrication system includes a steel bar processing and installation center, a concrete pouring center, a T-beam maintenance center, a T-beam tensioning and grouting center, and a beam yard intelligent monitoring center. The system is characterized in that the steel bar processing and installation center, the concrete pouring center, the T-beam maintenance center, and the T-beam tensioning and grouting center are respectively connected to the beam yard intelligent monitoring center.

[0009] Compared with the prior art, the present invention has obvious beneficial effects; from the above technical scheme, it can be known that: through the positioning of the mobile pedestal, the intelligent mobile pedestal realizes flexible start and stop, the high-precision positioning system ensures the movement safety, the web reinforcement is manufactured and installed, the reinforcement skeleton is divided into the bottom web and the top plate by the truss crane and hoisted into the mold as a whole, the tablet computer is used to control the attached vibrator and the vibrating rod to cast concrete, the web reinforcement is hoisted into the mold as a whole, the gantry is used to move and lift the T-beam to the construction site, the hydraulic formwork is closed, the two-stage oil cylinders on both sides push the formwork to close the mold respectively, the lifting oil cylinders on both sides push the formwork to move up and down for adjustment, the slope adjustment oil cylinders on both sides push the slope adjustment formwork to move up and down for slope adjustment, one-button mold closing, concrete pouring, the top plate reinforcement is manufactured and installed, and the formwork is made of the bottom formwork , side formwork and end formwork, using steel formwork, which meets the requirements of easy disassembly and assembly, stable strength and stiffness. The top plate steel bars are hoisted into the formwork as a whole, and the beam is moved horizontally to the grouting area by the gantry crane for grouting and anchoring. The T-beam concrete is mixed and transported. After the concrete reaches the conditions for demolding, the side formwork and end formwork are removed, and the beam is moved to the curing shed for steam curing through the mobile pedestal; after demolding, the mobile pedestal walking system is immediately started to send it to the steam curing room for steam curing, with a fast moving speed. Before the steam curing process begins, the steam curing process test is carried out according to the characteristics of the local project; high degree of intelligence: manifested in the use of intelligent mobile pedestals, intelligent hydraulic formworks, intelligent steam curing systems and intelligent tensioning equipment, which realize the automation and intelligent operation of the entire process from steel bar installation to concrete pouring, curing, tensioning, etc. Improved production efficiency: The production efficiency of the intelligent assembly line is 2.3 times that of the traditional process, and the qualified rate of the strength of the beam slab at the exit reaches 100%. Strict quality control: The intelligent control technology of the beam yard smart monitoring center ensures the precise control of various parameters during the construction process, thereby improving the quality and durability of the prefabricated beams.This production method not only improves production efficiency and quality control level, but also reduces labor costs and construction time. It is an efficient and environmentally friendly construction technology in modern bridge construction, which achieves a short production cycle and fast speed. The T-beams that are cured have stable quality and uniform color. Among them; the steel bar processing and installation center is to tie and install steel bars on the tire frame of the steel bar processing center; the concrete pouring center is to transport the concrete to the concrete pouring center through transportation equipment after the concrete is mixed, and use a tablet computer to control the attached vibrator and the vibrating rod to pour concrete in the T-beam formwork with one-click intelligent instant opening and closing; the T-beam curing center is to remove the side formwork and end formwork with one-click operation after the concrete reaches the demolding conditions, and move the beam to the steaming shed of the T-beam curing center through a mobile pedestal for curing. Environmentally friendly bio-particles are burned in the boiler room to generate steam, and the steam is transported to the steaming shed through pipelines. The intelligent steaming system is used to perform constant temperature and humidity curing according to the set temperature and humidity curve. After the steaming and curing is completed, the T-beam tensioning and grouting center moves the beam to the tensioning and grouting center, adopts intelligent tensioning equipment, and realizes precise tensioning of prestressed tendons through computer control technology. After the tensioning is completed, the anchor sealing operation is carried out and the prestressed duct is grouting treated to ensure the durability of the structure. The beam yard smart monitoring center is the main station of the beam yard smart monitoring center which monitors and controls the operations of the steel bar processing and installation center, concrete pouring center, T-beam maintenance center, and T-beam tensioning and grouting center. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 It is a process flow chart of the present invention; Figure 2 This is a schematic diagram of the one-button intelligent instant opening and closing T-beam template structure of the present invention; Figure 3 This is a schematic diagram of the structure of the mobile stand of the present invention. Figure 4 It is a system diagram of the present invention.

[0011] Marking in the figure; 1. Lifting cylinder, 2. Guide sleeve, 3. Support screw, 4. Slope-adjusting cylinder, 5. Formwork, 6. Slope-adjusting formwork, 7. Mobile pedestal, 71. Top plate, 72. Crossbeam, 73. Longitudinal beam, 74. Connecting seat, 75. Running wheel seat, 76. Running wheel, 78. Bottom plate, 79. Anti-fall device, 8. T-beam, 9. Track, 10. Two-stage cylinder, 11. Base. DETAILED DESCRIPTION

[0012] The specific implementation methods, structures, features and functions of the present invention are described in detail below in conjunction with the accompanying drawings and preferred embodiments.

[0013] An automated T-beam prefabrication production method of the present invention is characterized by comprising the following steps: 1) Positioning of the mobile pedestal: hoist the mobile pedestal onto the track in the concrete pouring area for positioning; 2) Fabrication and installation of web reinforcement: tying and installing reinforcement on the frame of the reinforcement processing center; 3) Lifting the web reinforcement into the formwork as a whole: transport the tied reinforcement cage as a whole to the concrete pouring center, and use a gantry crane to lift the web reinforcement cage as a whole into the formwork; 4) Hydraulic template closing: Use intelligent hydraulic template system to close the template; 5) Fabrication and installation of top plate reinforcement: Tie the top plate reinforcement on the frame of the reinforcement processing center, transport it to the concrete pouring center and wait for hoisting into the mold; 6) Lift the top plate reinforcement into the formwork as a whole: lift the top plate reinforcement into the formwork as a whole; 7) T-beam concrete mixing and transportation: After the concrete mixing is completed, it is transported to the concrete pouring center by transportation equipment; 8) T-beam concrete pouring: Use a tablet computer to control the attached vibrator and the vibrating rod to pour concrete in the T-beam formwork with one-button intelligent instant opening and closing; 9) T-beam demoulding and moving to the intelligent steam curing room: After the concrete reaches the demoulding conditions, the side and end forms are removed with one click, and the beam is moved to the steam curing shed of the T-beam curing center for curing through the mobile pedestal; 10) Combustion boiler to generate steam: Environmentally friendly biomass pellets are burned in the boiler room to generate steam, and the steam is transported to the steaming shed through pipelines; 11) Intelligent steam curing of T-beams: The intelligent steam curing system is used to perform constant temperature and humidity curing according to the set temperature and humidity curve; 12) Move the T-beam to the intelligent tensioning area: After steaming and curing, move the beam to the tensioning and grouting center; 13) Tensioning: Intelligent tensioning equipment is used to achieve precise tensioning of prestressed tendons through computer control technology; 14) Anchor sealing: After tensioning is completed, the anchor sealing operation is carried out; 15) Grouting: Grouting is performed on the prestressed holes to ensure the durability of the structure; 16) Hoisting to beam storage area / erection: Finally, the prefabricated T-beams are hoisted to the beam storage area or construction site for erection.

[0014] The one-button intelligent instant opening and closing T-beam formwork described in step 8) includes a lifting cylinder 1, a guide sleeve 2, a support screw 3, a slope adjustment cylinder 4, a formwork 5, a slope adjustment formwork 6, a movable pedestal 7, a track 9, a two-stage cylinder 10, and a base 11, characterized in that the lifting cylinder 1, the guide sleeve 2, and the two-stage cylinder 10 are respectively installed on the base 11, the lifting cylinder 1, the guide sleeve 2, and the two-stage cylinder 10 are respectively connected to the lower end of the formwork 5, the support screw 3, the slope adjustment cylinder 4, and the slope adjustment formwork 6 are respectively installed on the upper end of the formwork 5, the support screw 3 and the slope adjustment cylinder 4 are respectively connected to the slope adjustment formwork 6, the lower end of the formwork 5 is installed with a movable pedestal 7, and the movable pedestal 7 is installed on the track 9.

[0015] The mobile platform 7 includes a top plate 71, a cross beam 72, a longitudinal beam 73, a connecting seat 74, a running wheel seat 75, a running wheel 76, a bottom plate 78, and an anti-falling device 79, and is characterized in that: the running wheel seat 75 is inserted into the running wheel 76 insertion shaft, the running wheel 76 is placed on the track 9, the running wheel seat 75 is connected to the bottom plate 78 by bolts, the bottom plate 78 is connected to the longitudinal beam 73 by bolts, the cross beam 72 is fixedly installed on the longitudinal beam 73, the top plate 71 is installed on the cross beam 72, the connecting seat 74 is fixedly installed on the side of the longitudinal beam 73, and the anti-falling device 79 is installed on the connecting seat 74.

[0016] Step 10) The steaming shed is a closed steaming shed.

[0017] An automated T-beam prefabrication system includes a steel bar processing and installation center, a concrete pouring center, a T-beam maintenance center, a T-beam tensioning and grouting center, and a beam yard intelligent monitoring center. The system is characterized in that the steel bar processing and installation center, the concrete pouring center, the T-beam maintenance center, and the T-beam tensioning and grouting center are respectively connected to the beam yard intelligent monitoring center.

[0018] The above contents are further detailed descriptions of the present invention in combination with specific preferred embodiments, and it cannot be determined that the specific implementation of the present invention is limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, several simple deductions or substitutions can be made without departing from the concept of the present invention, which should be regarded as falling within the protection scope of the present invention.

Claims

1. A production method for automated T-beam prefabrication, characterized in that: The steps include: 1) Positioning of the mobile pedestal: hoist the mobile pedestal onto the track in the concrete pouring area for positioning; 2) Fabrication and installation of web reinforcement: tying and installing reinforcement on the frame of the reinforcement processing center; 3) Lifting the web reinforcement into the formwork as a whole: transport the tied reinforcement cage as a whole to the concrete pouring center, and use a gantry crane to lift the web reinforcement cage as a whole into the formwork; 4) Hydraulic template closing: Use intelligent hydraulic template system to close the template; 5) Fabrication and installation of top plate reinforcement: Tie the top plate reinforcement on the frame of the reinforcement processing center, transport it to the concrete pouring center and wait for hoisting into the mold; 6) Lift the top plate reinforcement into the formwork as a whole: lift the top plate reinforcement into the formwork as a whole; 7) T-beam concrete mixing and transportation: After the concrete mixing is completed, it is transported to the concrete pouring center by transportation equipment; 8) T-beam concrete pouring: Use a tablet computer to control the attached vibrator and the vibrating rod to pour concrete in the T-beam formwork with one-button intelligent instant opening and closing; 9) T-beam demoulding and moving to the intelligent steam curing room: After the concrete reaches the demoulding conditions, the side and end forms are removed with one click, and the beam is moved to the steam curing shed of the T-beam curing center for curing through the mobile pedestal; 10) Combustion boiler to generate steam: Environmentally friendly biomass pellets are burned in the boiler room to generate steam, and the steam is transported to the steaming shed through pipelines; 11) Intelligent steam curing of T-beams: The intelligent steam curing system is used to perform constant temperature and humidity curing according to the set temperature and humidity curve; 12) Move the T-beam to the intelligent tensioning area: After steaming and curing, move the beam to the tensioning and grouting center; 13) Tensioning: Intelligent tensioning equipment is used to achieve precise tensioning of prestressed tendons through computer control technology; 14) Anchor sealing: After tensioning is completed, the anchor sealing operation is carried out; 15) Grouting: Grouting is performed on the prestressed holes to ensure the durability of the structure; 16) Hoisting to beam storage area / erection: Finally, the prefabricated T-beams are hoisted to the beam storage area or construction site for erection.

2. The method for automated T-beam prefabrication as claimed in claim 1, characterized in that: The one-key intelligent instant opening and closing T-beam template described in step 8) comprises a lifting cylinder (1), a guide sleeve (2), a support screw (3), a slope adjustment cylinder (4), a template (5), a slope adjustment template (6), a movable pedestal (7), a track (9), a two-stage cylinder (10), and a base (11), characterized in that the lifting cylinder (1), the guide sleeve (2), and the two-stage cylinder (10) are respectively installed on the base (11), the lifting cylinder (1), the guide sleeve (2), and the two-stage cylinder (10) are respectively connected to the lower end of the template (5), the support screw (3), the slope adjustment cylinder (4), and the slope adjustment template (6) are respectively installed on the upper end of the template (5), the support screw (3) and the slope adjustment cylinder (4) are respectively connected to the slope adjustment template (6), the lower end of the template (5) is installed with a movable pedestal (7), and the movable pedestal (7) is installed on the track (9).

3. The method for automated T-beam prefabrication as claimed in claim 2, characterized in that: The mobile platform (7) comprises a top plate (71), a cross beam (72), a longitudinal beam (73), a connecting seat (74), a running wheel seat (75), a running wheel (76), a bottom plate (78), and an anti-falling device (79), and is characterized in that: a running wheel (76) insertion shaft is placed in the running wheel seat (75), the running wheel (76) is placed on the track (9), the running wheel seat (75) is connected to the bottom plate (78) by bolts, the bottom plate (78) is connected to the longitudinal beam (73) by bolts, the cross beam (72) is fixedly mounted on the longitudinal beam (73), the top plate (71) is mounted on the cross beam (72), a connecting seat (74) is fixedly mounted on the side of the longitudinal beam (73), and the anti-falling device (79) is mounted on the connecting seat (74).

4. The method for automated T-beam prefabrication as claimed in claim 1, characterized in that: Step 10) The steaming shed is a closed steaming shed.

5. An automated T-beam prefabrication system, including a steel bar processing and installation center, a concrete pouring center, a T-beam maintenance center, a T-beam tensioning and grouting center, and a beam yard intelligent monitoring center, characterized in that: The steel bar processing and installation center, concrete pouring center, T-beam maintenance center, and T-beam tensioning and grouting center are respectively connected to the beam yard intelligent monitoring center.

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