A kind of water pier column casting device and construction method thereof

Abstract

The present invention discloses an apparatus for casting a pier column on water, which belongs to the technical field of casting a pier column on water. The apparatus comprises a pontoon platform with a positioning column arranged at the bottom, and a clamping mechanism is arranged on the left and right sides of the top of the pontoon platform. The single clamping mechanism is composed of a first fixed rail, a movable base, a telescopic cylinder, a column, a second fixed rail, an electric telescopic rod, a mounting frame, a third drive motor, a driving gear, a driven gear, a bidirectional threaded rod, and a clamping plate. Through the design of the pontoon platform and the positioning column, the present invention can provide a stable working platform on the water surface, ensuring stability and safety during the construction process. The components such as the telescopic cylinder, the drive motor and the electric telescopic rod in the apparatus realize automatic positioning, clamping and height adjustment of the template, reduce manual operation, improve construction efficiency, and can quickly complete the installation of the template and concrete pouring, shortening the construction period. The present invention also provides a method for casting a pier column on water.

Description

Technical Field

[0001] The invention belongs to the field of water pier column casting technology and provides an water pier column casting device and a construction method thereof. Background Art

[0002] Piers are a common substructure of bridges, and the quality of their concrete construction plays a crucial role in the overall stability of the bridge. Traditional water-based pier casting often involves poor stability, complex operation, and low efficiency. Furthermore, these devices often require extensive manual labor, increasing both construction costs and risks. Furthermore, traditional construction methods present numerous challenges in formwork positioning, adjustment, and fixation, making it difficult to ensure construction accuracy. Furthermore, the construction process has a significant impact on the environment, hindering sustainable development. Summary of the Invention

[0003] In light of this, the present invention aims to provide a robust, easily adjustable, and easily adjustable overwater pier casting device, effectively addressing the issues of poor stability, complex operation, and low efficiency inherent in traditional construction methods. Another object of the present invention is to provide an overwater pier casting method that improves construction accuracy and efficiency, reduces construction risks, and promotes the sustainable development of bridge construction.

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

[0005] The present invention provides an apparatus for casting pier columns on water, comprising a pontoon platform with a positioning column arranged at the bottom, a clamping mechanism provided on each of the left and right sides of the top of the pontoon platform, wherein the clamping mechanism comprises a first fixed rail, a movable base, a telescopic cylinder, a column, a second fixed rail, an electric telescopic rod, a mounting frame, a third drive motor, a driving gear, a driven gear, a bidirectional threaded rod, and a clamping plate, wherein the first fixed rail and the telescopic cylinder are both mounted on the pontoon platform, the output end of the telescopic cylinder is connected to the movable base, and the movable base is slidably mounted within the first fixed rail; the column is mounted on the movable base; the second fixed rail is mounted on the column; the mounting frame is mounted on the second fixed rail via the electric telescopic rod; the third drive motor is mounted within the mounting frame, and the output end of the third drive motor is connected to the driving gear; two clamping plates are provided, each slidably mounted within the mounting frame, and a bidirectional threaded rod with a driven gear is provided between the two clamping plates, and the driving gear and the driven gear are meshed for transmission. In this way, the positioning column and the pontoon platform design ensure the stability of the apparatus during construction on water and can withstand fluctuations on the water surface. The clamping mechanism, through the cooperation of sliding rails and cylinders, enables rapid and precise positioning and adjustment of the formwork, improving construction accuracy. Furthermore, the use of an electric telescopic rod and drive motor simplifies operation, reduces manual intervention, and improves work efficiency. This device is designed with safety in mind during construction, reducing risks associated with unstable formwork.

[0006] Optionally, the mold clamping mechanism further includes a first drive motor, a drive gear, and a connecting gear, wherein the first drive motor is fixedly mounted on the movable base, the drive gear and the column are both rotatably mounted on the movable base, the connecting gear is sleeved onto the column, and the output end of the first drive motor is connected to the drive gear, which meshes with the drive gear for transmission. In this way, the rotation of the connecting gear can effectively drive other components of the mold clamping mechanism, thereby realizing the rotation function of the column.

[0007] Optionally, the mold clamping mechanism further includes a second drive motor, an output shaft, a threaded rod, and a movable mounting plate, wherein the second drive motor is fixedly mounted on the column, the threaded rod is rotatably mounted on the second fixed rail, and the output shaft of the second drive motor is connected to the threaded rod. The movable mounting plate is slidably mounted on the second fixed rail and threadably connected to the threaded rod. The second drive motor causes the threaded rod to rotate, thereby enabling the movable mounting plate to move axially along the threaded rod, thereby achieving displacement of the associated components.

[0008] Optionally, the clamping mechanism also includes a guide rod disposed between the two clamping plates. This guide rod helps maintain the relative position of the clamping plates 22, ensuring that the clamping plates apply force evenly during the clamping process, thereby improving the stability and consistency of the clamping. The two clamping plates are provided with serrations on their respective facing surfaces. This structure enables the clamping mechanism to better lock the workpiece during clamping, ensuring its safety and stability during processing or operation. This allows the clamping mechanism to achieve a stronger clamping effect and higher operational reliability.

[0009] Optionally, the casting device also includes at least one casting pipe arranged on the top of the pontoon platform, which is mainly used to transport casting materials (such as concrete or other liquid materials) to the required casting position, and the pontoon platform 1 provides a stable support structure and provides the necessary space and support for the setting of the casting pipe.

[0010] Optionally, the pouring pipe adopts a telescopic structure. A third fixed track with a screw is installed on the pontoon platform. A sliding bracket is installed on the pouring pipe. The sliding bracket slides on the third fixed track and is threadedly connected to the screw. This design allows the pouring pipe to be extended and retracted as needed to meet pouring requirements. The combination of the fixed track with a screw and the sliding bracket provides flexible height adjustment.

[0011] Optionally, multiple pouring pipes can share a third fixed rail, screw, and sliding bracket. This allows for centralized management and control of the pouring pipes. This design not only simplifies the device structure but also reduces the number of required components, thereby lowering manufacturing and maintenance costs.

[0012] The present invention is also based on the construction method of the above-mentioned water pier column casting device, which includes the following steps:

[0013] 1) Install the upper buoyancy platform using positioning columns;

[0014] 2) Start the electric telescopic rod to drive the installation frame to rise and fall, and move the two splints to the clamping position of the template;

[0015] 3) Start the third drive motor, and the driving gear rotates to drive the driven gear and the bidirectional threaded rod to rotate, so that the two clamping plates make synchronous relative displacement with the assistance of the bidirectional threaded rod and the guide rod, and clamp the template;

[0016] 4) Start the electric telescopic rod to drive the installation frame to rise and fall to adjust the Z-direction position of the template clamped by the two clamping plates;

[0017] 5) Start the second drive motor, and the threaded rod rotates to drive the movable mounting plate to move horizontally to adjust the Y-axis position of the template clamped by the two clamping plates;

[0018] 6) Start the telescopic cylinder to drive the movable base to move horizontally to adjust the X-axis position of the template clamped by the two clamping plates;

[0019] 7) Connect the feed port of the pouring pipe to the outlet of the concrete machine. The staff on the floating platform manually controls the discharge port of the pouring pipe to allow the concrete to enter the formwork to complete the pouring.

[0020] Preferably, before step 2), the first driving motor is started, and the driving gear rotates to drive the connecting gear and the column to rotate, so that the mounting frame is rotated out of the pontoon platform or retracted into the pontoon platform.

[0021] Preferably, in step 7), the worker manually rotates the driving screw to adjust the X-direction position of the casting pipe.

[0022] The beneficial effects of the present invention are as follows: the above-water pier column casting device, through the design of the pontoon platform and the positioning column, can provide a stable working platform on the water surface, ensuring stability and safety during the construction process, and the components such as the telescopic cylinder, the drive motor and the electric telescopic rod in the device realize automatic positioning, clamping and height adjustment of the template, reducing manual operation and improving construction efficiency. Through the precise control of the electric telescopic rod and the drive motor, the template can be accurately positioned and adjusted, and the construction accuracy is improved. Through the integrated construction process, the device can quickly complete the installation of the template and the pouring of concrete, shortening the construction period.

[0023] Other advantages, objects, and features of the present invention will be described in part in the following description and, in part, will be apparent to those skilled in the art upon examination of the following description or may be learned from practice of the present invention. The objects and other advantages of the present invention may be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be described in detail below with reference to the accompanying drawings, in which:

[0025] Figure 1 It is a front perspective structural diagram of the above-water pier casting device of the present invention;

[0026] Figure 2 It is a top view of the three-dimensional structure of the above-water pier casting device of the present invention;

[0027] Figure 3 for Figure 1 Schematic diagram of the partially exploded three-dimensional structure of the clamping mechanism;

[0028] Figure markings: 1- pontoon platform; 2- positioning column; 3- first fixed rail; 4- movable base; 5- telescopic cylinder; 6- first drive motor; 7- drive gear; 8- column; 9- connecting gear; 10- second fixed rail; 11- second drive motor; 12- output shaft; 13- threaded rod; 14- movable mounting plate; 15- electric telescopic rod; 16- mounting frame; 17- third drive motor; 18- driving gear; 19- driven gear; 20- bidirectional threaded rod; 21- guide rod; 22- splint; 23- third fixed rail; 24- screw rod; 25- sliding bracket; 26- casting pipe. DETAILED DESCRIPTION

[0029] The present invention is further described below with reference to specific embodiments. The accompanying drawings are for illustrative purposes only and are schematic, not actual, representations. They should not be construed as limiting this patent. To better illustrate the embodiments of the present invention, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted from the drawings.

[0030] like Figure 1-3As shown, the apparatus for casting a pier column on water disclosed herein comprises a pontoon platform 1 with positioning columns 2 disposed at its bottom. These columns effectively enhance the stability of the pontoon platform 1, ensuring safety during construction. The pontoon platform 1 is also convenient for maneuvering on the water. A clamping mechanism is located on each side of the top of the pontoon platform 1, flexibly clamping and positioning the formwork (not shown), ensuring its accuracy and stability during the casting process. A single clamping mechanism consists of a first fixed rail 3, a movable base 4, a telescopic cylinder 5, a column 8, a second fixed rail 10, an electric telescopic rod 15, a mounting frame 16, a third drive motor 17, a driving gear 18, a driven gear 19, a bidirectional threaded rod 20, and a clamping plate 22. The first fixed rail 3 and the telescopic cylinder 5 are both mounted on the pontoon platform 1, the output end of the telescopic cylinder 5 is connected to the movable base 4, and the movable base 4 is slidably arranged in the first fixed rail 3, that is, the first fixed rail 3 provides a sliding rail for the movable base 4, and the movable base 4 is driven by the telescopic cylinder and can move on the first fixed rail 3 to adjust the position of the template; the column 8 is arranged on the movable base 4 to support the upper structure; the second fixed rail 10 is arranged on the column 8 to provide a mounting frame A sliding rail is provided to achieve adjustment of the horizontal position; the mounting frame 16 is arranged on the second fixed rail 10 through the electric telescopic rod 15 to further adjust the height and position of the template; the third drive motor 17 is arranged in the mounting frame 16, responsible for driving the movement of the splint, and the output end of the third drive motor 17 is connected to the driving gear 18; there are two splints 22, which are slidably arranged in the mounting frame 16 respectively, and a bidirectional threaded rod 20 with a driven gear 19 is provided between the two splints 22, which can achieve precise control and adjustment of the splint 22, and the driving gear 18 and the driven gear 19 are engaged for transmission to achieve synchronous movement of the splint 22, that is, the splint 22 can be clamped and released under the drive of the electric telescopic rod 15 and the third drive motor 17, which is convenient for rapid replacement and adjustment of the template. Using this solution, the pontoon platform is transported to the construction site, where positioning columns are installed to ensure stability. The clamping mechanism is then adjusted according to the pier's design dimensions using telescopic cylinders and electric telescopic rods. Clamps are then used to hold the formwork, assisting in its installation and ensuring it meets construction requirements and does not shift before pouring. Concrete is then pumped into the formwork via a concrete delivery system for pouring. Finally, after the concrete solidifies, the formwork is removed and the construction site cleaned. This overwater pier casting device effectively improves the accuracy and efficiency of overwater construction, ensuring the quality and safety of bridge construction.

[0031] In this embodiment, the clamping mechanism further includes a first drive motor 6, a drive gear 7, and a connecting gear 9, wherein the first drive motor 6 is fixedly mounted on the movable base 4 to provide the necessary power source, the drive gear 7 and the column 8 are both rotatably mounted on the movable base 4 to ensure their stability and reliability during operation, the connecting gear 9 is sleeved on the column 8, and plays a role in connection and transmission, and the output end of the first drive motor 6 is connected to the drive gear 7, and the connecting gear 9 is meshed with the drive gear 7 for transmission. In this way, the drive gear 7 drives the connecting gear 9 to rotate through the first drive motor 6, thereby making the column 8 rotatable relative to the movable base 4, and further making the second fixed rail 10, the mounting frame and its upper clamping plate 22 arranged on the column 8 also rotatable, that is, the mounting frame and its upper clamping plate 22 can be rotated out of the pontoon platform 1 or retracted into the pontoon platform 1, or the mounting frame and its upper clamping plate 22 can be rotated from one side of the pontoon platform 1 to the other adjacent side.

[0032] In this embodiment, the clamping mechanism also includes a second drive motor 11, an output shaft 12, a threaded rod 13 and a movable mounting plate 14, wherein the second drive motor 11 is fixedly arranged on the column 8, serving as one of the power sources of the system and providing the necessary rotational power, the threaded rod 13 is rotatably arranged on the second fixed track 10, allowing the rotation of the motor to directly drive the rotation of the threaded rod 13, and the output shaft 12 of the second drive motor 11 is connected to the threaded rod 13, and the movable mounting plate 14 is slidably arranged on the second fixed track 10 and is threadedly connected to the threaded rod 13, and can achieve linear movement through rotation. Through the rotation of the threaded rod, the movable mounting plate 14 can move linearly along the track, thereby achieving precise adjustment of the clamping mechanism. Of course, in different embodiments, a rotary motor can also be provided between the movable mounting plate 14 and the electric telescopic rod 15 to rotate the mounting frame and the clamping plate 22 thereon to better adjust the clamping orientation of the template.

[0033] In this embodiment, the clamping mechanism also includes a guide rod 21 arranged between the two clamping plates 22, which plays a guiding and supporting role. The two clamping plates 22 are provided with serrations (not shown) on their respective facing surfaces. The serration design can increase the friction between the clamping plates 22 and the object to be clamped, preventing the clamped object from sliding during the clamping process.

[0034] In this embodiment, the pouring device further comprises at least one pouring pipe 26 provided on the top of the pontoon platform 1. By providing the pouring pipe 26 on the top of the pontoon platform 1, the pouring process is optimized, and a more efficient and accurate pouring operation is achieved.

[0035] In this embodiment, the pouring pipe 26 utilizes a telescopic structure, facilitating adjustment of the pouring outlet to suit pouring requirements. A third fixed track 23 with a screw 24 is provided on the pontoon platform 1, providing a guide path for a sliding bracket 25. The sliding bracket 25 is mounted on the pouring pipe 26 and slides onto the third fixed track 23 and is threadedly connected to the screw 24. The fixed track design ensures the sliding bracket remains stable during movement, preventing unnecessary shaking or deflection. Rotating the screw allows the sliding bracket to be controlled, enabling precise adjustment of the pouring pipe's translation.

[0036] In this embodiment, multiple pouring pipes 26 share a set of third fixed rails 23, screws 24, and sliding brackets 25. By sharing a set of rails and screw systems, the operator can conveniently use multiple pouring pipes, especially when multiple pouring operations need to be performed simultaneously, which can improve work efficiency.

[0037] The present invention is also based on the construction method of the above-mentioned water pier column casting device, which includes the following steps:

[0038] 1) Install the pontoon platform. Use positioning columns 2 to accurately position the pontoon platform 1 at the designated location within the pier construction area. Ensure the pontoon platform is level and stable for subsequent operations, and that it can be easily moved between different positioning columns. Also, ensure the water depth and current conditions are met to ensure the pontoon platform is not affected by strong currents and drift. Check the positioning columns for stability to prevent them from loosening during construction.

[0039] 2) Start the first drive motor. The first drive motor 6 starts rotating the drive gear 7. This rotation drives the connecting gear 9 and the column 8, thereby rotating the mounting frame out of the pontoon platform 1. Then, activate the electric telescopic rod 15 to raise and lower the mounting frame, moving the two clamps 22 to the clamping position on the template. Important: Before starting the motor, ensure all operators maintain a safe distance and that the surrounding area is clear of obstacles. Monitor the motor's operating status to ensure there are no abnormal noises or vibrations.

[0040] 3) Clamp the formwork. Start the third drive motor 17, which rotates the driving gear 18, driving the driven gear 19 and the bidirectional threaded rod 20. With the assistance of the bidirectional threaded rod and guide rod, the two clamps will synchronously move relative to each other, clamping the formwork. Ensure there is no foreign matter between the clamps and the formwork to prevent loose clamping. Monitor the clamping force to avoid overtightening and causing formwork deformation.

[0041] 4) Adjust the Z-axis position. Activate the electric telescopic rod 15 again and adjust the height of the mounting frame to precisely adjust the Z-axis position (vertical height) of the template between the two clamping plates 22. During this adjustment, ensure that the template does not collide with the surrounding environment. Verify that the height meets construction specifications and design requirements.

[0042] 5) Adjust the Y-axis position. Start the second drive motor 11 to rotate the threaded rod 13, which in turn moves the movable mounting plate 14, thereby adjusting the Y-axis position (left and right) of the two clamping plates. Note: Ensure the template remains stable during adjustment to avoid shifting or tilting due to movement.

[0043] 6) Adjust the X-axis position. Activate the telescopic cylinder 5 to drive the movable base 4 to move horizontally to adjust the X-axis position (front-back position) of the two clamping plates. Also note: When making adjustments, pay attention to the surrounding water environment to ensure the stability of the equipment during water operations.

[0044] 7) Connect the pouring pipe. Connect the inlet of the pouring pipe 26 to the outlet of the concrete machine, ensuring a secure and leak-proof connection. From the pontoon platform 1, a worker manually controls the outlet of the pouring pipe to deliver concrete into the formwork, completing the pour. Also, note: During the pouring process, monitor the flow of the concrete to ensure uniform placement. Also, pay attention to the pouring speed to avoid uneven concrete distribution due to pouring too quickly.

[0045] 8) Adjust the pouring pipe position. The operator manually rotates the drive screw 24 to adjust the X-axis position of the pouring pipe to ensure that the concrete accurately enters all parts of the formwork. Also note: Ensure that the operator pays attention to safety during the adjustment process to avoid being pinched by moving parts.

[0046] 9) Retract after pouring. After pouring is complete, start the first drive motor 6, which drives the gear 7 to rotate, driving the connecting gear 9 and the column 8 to retract the mounting frame into the pontoon platform 1. Also, note: Check the pouring progress to ensure that the concrete has completely filled the formwork. When retracting the mounting frame, ensure that the surrounding area is clear of obstacles to avoid collisions.

[0047] The detailed steps above ensure efficient, accurate, and safe pouring of the water pier. Each step should be performed strictly in accordance with the operating procedures to improve construction quality and efficiency while ensuring the safety of the construction personnel.

[0048] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions, which should all be included in the scope of the claims of the present invention.

Claims

1. An above-water pier casting device, characterized in that: The invention comprises a pontoon platform (1) with a positioning column (2) arranged at the bottom, a clamping mechanism is respectively arranged on the left and right sides of the top of the pontoon platform (1), and a single clamping mechanism is composed of a first fixed rail (3), a movable base (4), a telescopic cylinder (5), a column (8), a second fixed rail (10), an electric telescopic rod (15), a mounting frame (16), a third drive motor (17), a driving gear (18), a driven gear (19), a bidirectional threaded rod (20), and a clamping plate (22), wherein the first fixed rail (3) and the telescopic cylinder (5) are both installed on the pontoon platform (1), the output end of the telescopic cylinder (5) is connected to the movable base (4), and the movable base (4) is connected to the output end of the telescopic cylinder (5). The movable base (4) is slidably mounted in the first fixed rail (3); the column (8) is mounted on the movable base (4); the second fixed rail (10) is mounted on the column (8); the mounting frame (16) is mounted on the second fixed rail (10) via the electric telescopic rod (15); the third drive motor (17) is mounted in the mounting frame (16), and the output end of the third drive motor (17) is connected to a driving gear (18); two clamping plates (22) are provided, each of which is slidably mounted in the mounting frame (16), and a bidirectional threaded rod (20) with a driven gear (19) is provided between the two clamping plates (22), and the driving gear (18) and the driven gear (19) are meshed for transmission; The clamping mechanism further comprises a first driving motor (6), a driving gear (7) and a connecting gear (9), wherein the first driving motor (6) is fixedly arranged on the movable base (4), the driving gear (7) and the column (8) are both rotatably arranged on the movable base (4), the connecting gear (9) is sleeved on the column (8), and the output end of the first driving motor (6) is connected to the driving gear (7), and the connecting gear (9) and the driving gear (7) are meshed and transmitted; The clamping mechanism further includes a second drive motor (11), an output shaft (12), a threaded rod (13) and a movable mounting plate (14), wherein the second drive motor (11) is fixedly arranged on the column (8), the threaded rod (13) is rotatably arranged on the second fixed rail (10), and the output shaft (12) of the second drive motor (11) is connected to the threaded rod (13), and the movable mounting plate (14) is slidably arranged on the second fixed rail (10) and is threadably connected to the threaded rod (13); The pouring device further comprises at least one pouring pipe (26) arranged on the top of the pontoon platform (1).

2. The above-water pier casting device according to claim 1, characterized in that: The clamping mechanism further comprises a guide rod (21) arranged between two clamping plates (22), and the two clamping plates (22) are provided with saw teeth on their respective facing corresponding surfaces.

3. The above-water pier casting device according to claim 2, characterized in that: The pouring pipe (26) adopts a telescopic structure. A third fixed track (23) with a screw rod (24) is provided on the pontoon platform (1). A sliding bracket (25) is provided on the pouring pipe (26). The sliding bracket (25) is slidably arranged on the third fixed track (23) and is threadedly connected to the screw rod (24).

4. The above-water pier casting device according to claim 3, characterized in that: The plurality of pouring pipes (26) share a set of third fixed rails (23), screw rods (24) and sliding brackets (25).

5. The construction method of the water pier column casting device according to claim 4 is characterized in that: The steps include: 1) Use positioning columns to install the upper buoyancy platform; 2) Start the electric telescopic rod to drive the installation frame to rise and fall, and move the two clamping plates to the clamping position of the template; 3) Start the third drive motor, and the driving gear rotates to drive the driven gear and the bidirectional threaded rod to rotate, so that the two clamping plates make synchronous relative displacement with the assistance of the bidirectional threaded rod and the guide rod, and clamp the template; 4) Start the electric telescopic rod to drive the installation frame to move up and down to adjust the Z-axis position of the template clamped by the two clamping plates; 5) Start the second drive motor, and the threaded rod rotates to drive the movable mounting plate to move horizontally to adjust the Y-axis position of the template clamped by the two clamping plates; 6) Start the telescopic cylinder to drive the movable base to move horizontally to adjust the X-axis position of the template clamped by the two clamping plates; 7) Connect the feed port of the pouring pipe to the outlet of the concrete machine. The staff on the floating platform manually controls the discharge port of the pouring pipe to allow the concrete to enter the formwork to complete the pouring.

6. The construction method according to claim 5, characterized in that: Before step 2), the first driving motor is started, and the driving gear rotates to drive the connecting gear and the column to rotate, so that the mounting frame is rotated out of the pontoon platform or retracted into the pontoon platform.

7. The construction method according to claim 5, characterized in that: In step 7), the worker manually rotates the drive screw to adjust the X-axis position of the casting pipe.

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