Industrialized intelligent technical method for precast beam field

Abstract

The invention discloses an industrial intelligent technical method for a precast beam field. The industrial intelligent technical method comprises the following processes of steel bar machining, corrugated pipe mounting, formwork mounting, concrete pouring, concrete curing, prestress tensioning, grouting and anchor sealing, beam plate hoisting and storing. The construction technical method comprises the following steps: firstly, binding a processed and formed steel reinforcement framework, arranging a corrugated pipe for forming a prestressed tendon pore channel, then mounting a special template of a beam body, pouring concrete, maintaining, removing a side template after the concrete reaches a certain strength, and continuously maintaining, so as to form the prestressed tendon pore channel. And after the concrete strength meets the design requirement, pre-stress cable penetrating is conducted, pre-stress ribs are tensioned and anchored in sequence, then grouting and anchor sealing procedures are conducted, prefabrication of a beam body is completed, and finally the beam body is hoisted and conveyed to a preset position to be stored. The construction process is intelligent, the steel bar binding and machining efficiency is improved, the prestress tensioning precision and quality are improved, the grouting process difficulty is reduced, and operation is easier.

Description

Technical Field

[0001] The invention belongs to the technical field of prefabricated beams, and in particular relates to an industrialized intelligent technical method for a prefabricated beam field. Background Art

[0002] At present, prefabricated beams are widely used in domestic bridge construction. How to improve production efficiency and product quality while reducing production costs has become an urgent problem to be solved in this industry. To this end, the present invention provides an industrialized intelligent technology method for a prefabricated beam field.

[0003] The invention patent application with application publication number CN 115556231 A discloses the "Standardized, Informationized, and Factory-based Prefabricated Box Girder Construction Method". The construction method includes: the installation of the outer template is completed in one installation, the template surface is cleaned before installation, and a release agent is applied. The installation of the outer template is hoisted by a door crane. During the installation process, the template is installed symmetrically from one end of the pedestal to the other end on the left and right sides. The tension rods should be locked in time during installation. The installation of the inner and end templates includes the installation of the inner and end templates. The installation of the inner template is installed in one installation, the divided templates are assembled, and the joints are treated with stop grout strips at the connection. After the overall assembly, it is installed; the installation of the end template is installed by a fixed steel template, and a foam sealant is used to stop grouting at the reserved hole gap. In contrast, the present invention adopts an automated template system, and the outer template can be installed in place and removed backwards through a hydraulic system. The inner template can be automatically separated from the beam body through a hydraulic system, and the overall installation, overall removal, and overall movement of the template are realized. Repeated hoisting is not required, which improves construction efficiency and improves the quality of beam and slab prefabrication.

[0004] The invention patent application with publication number CN 113001753 B discloses "An intelligent box beam prefabrication method", which includes: installing a sliding platform device on the top plate steel cage positioning frame, the sliding platform device includes a platform across the top plate steel cage positioning frame, columns installed at both ends of the platform and running wheels installed at the bottom of the columns, and the top plate steel cage positioning frame is provided with two parallel linear tracks that match the running wheels; tying multiple top plate transverse stirrups and multiple top plate longitudinal steel bars of the top plate steel cage on the top plate steel cage positioning frame, and then the construction personnel stand on the platform to tie the top plate door-shaped steel bars. In comparison, the present invention uses intelligent steel bar CNC processing technology, including six core technologies: CNC steel bar sawing and threading production line, CNC steel bar bar shearing production line, CNC vertical steel bar bending center, intelligent steel bar bending hoop production line, steel cage rolling welding robot production line and cap beam skeleton welding robot. The product has standardized shape, accurate size, stable mechanical properties, improved production efficiency, improved steel bar processing accuracy, and reduced labor intensity of workers. Summary of the invention

[0005] In order to solve the problems of low production efficiency and low product precision in the traditional production method of precast beams, the present invention provides an industrial intelligent technology method for a precast beam field.

[0006] The technical solution of the present invention is as follows: An industrial intelligent technology method for a prefabricated beam yard is characterized by comprising four core equipments: a CNC steel bar sawing and threading production line, a CNC steel bar bar shearing production line, a CNC vertical steel bar bending center and a cap beam skeleton welding robot.

[0007] Further preferably, the CNC steel bar sawing and threading production line adopts a streamlined design concept and has a multi-level raw material and finished product storage mechanism. The raw materials are transported to the sawing main machine through the storage platform and completed with high-speed sawing (the sawing processing mode can avoid the horseshoe-shaped incision of the steel bar, which is convenient for the subsequent threading operation). After the sawing is completed, the steel bar is transported to the threading guide platform, and the two ends of the steel bar are threaded respectively through the conveyor roller. The entire working cycle is automatic, and the equipment can be started after the steel bars to be processed are placed.

[0008] Further optimization, the CNC steel bar shearing production line adopts advanced programmable CNC and PLC systems as the equipment control core, which is more stable and efficient in operation and has strong expansion capabilities. The cutting length can be set arbitrarily and the task category can be set to work continuously. The overall work is coherent, the bar and steel bar conveying speed is fast, and the steel bar rack conveying device (positive and negative rotation) can flexibly convey steel bars, and the fixed-length cutting accuracy is high. Incorporating the concept of standardization of steel bar processing, the equipment has been designed for application expansion. Through professional technical transformation, it is easy to combine and expand the modular combination of cutting and bending production and various processing equipment, and has the ability to work perfectly with professional cranes.

[0009] Further preferred, the CNC vertical steel bar bending center adopts a touch screen and PLC control system, including a two-head vertical bending center and a mobile bending main machine, equipped with PLC and CNC control, and the processing setting operation is very simple. It can store up to hundreds of graphics, which can be set up and reused once, and is easy to operate with a touch screen control panel. The two-head vertical bending center is specially equipped with a dual CNC servo positioning system, which realizes high-precision bidirectional bending in one working unit at the same time, while ensuring the processing efficiency and control accuracy of the equipment. The two bending main machines work at the same time and can bend multiple steel bars at the same time. The mobile bending main machine can freely set the bending length, and the servo control and flexible steel bar locking mechanism ensure accuracy. The integrated high-strength mobile track design and the high-strength loading rack that can carry 5 tons of raw materials greatly reduce the labor intensity.

[0010] Further preferred, the cap beam skeleton welding robot is mainly composed of a robot walking axis unit (ground rail), a six-axis linkage welding robot, a welding platform, an automatic clamp and an electrical operating system. It is an automated and intelligent welding equipment for welding steel skeleton sheets of cap beams. The robot walking axis unit (ground rail) adopts a gear rack transmission. As the seventh axis unit of the welding robot, it is used for walking in the X-axis direction of the robot. It adopts a full servo power system to achieve stable walking, high precision, and good dust and anti-fouling properties. The six-axis linkage welding robot is equipped with a visual weld tracking system. It uses photography technology and millisecond-level data acquisition response to accurately determine the three-dimensional position of the weld. The steel bar weld deviation does not require manual intervention, thereby achieving high-quality welding and saving labor. The automatic clamp uses pneumatic / hydraulic methods to drive the clamp to clamp the steel bars in advance to enhance the quality of welds.

[0011] Further preferably, the automated formwork includes an automated integral hydraulic formwork (external formwork) and an automated box beam inner formwork system (inner formwork). The outer formwork consists of three parts: a formwork system, a hydraulic system, and a walking system. The formwork system is similar to the structure of an ordinary steel formwork, and the formwork blocks are larger; the hydraulic system is attached and supported on the outer formwork, and the formwork can be installed in place and removed backward through the hydraulic system; the walking system is for transporting the formwork, and it moves the formwork between different rows of pedestals in the prefabricated pedestal area through the longitudinal track. The main advantages of the integral hydraulic formwork are: first, it can be installed, removed, and moved as a whole, without repeated lifting; second, it does not need to be disassembled during construction (except for replacing formwork parts). The inner formwork consists of three parts: a formwork system, a hydraulic system, and a traction system. The formwork system is similar to the structure of an ordinary steel formwork; the hydraulic system is attached and supported on the inner formwork, and the inner formwork can be automatically separated from the beam body through the hydraulic system; the traction system is mainly composed of a winch at the front end of the beam body. The advantages of the automated box beam inner formwork system are similar to those of the integral hydraulic formwork.

[0012] Further preferred, the automatic spray curing system adopts automatic control and wireless sensing technology, and its main components are: intelligent cloud controller, wireless network card, electromagnetic water valve, booster pump, pipeline system and automatic telescopic rotating nozzle. Through software systems, control equipment and other information means, the prefabricated beams can be fully automatically and intelligently sprayed and cured; the curing of each beam-making pedestal is independently controlled, and the prefabrication of the adjacent pedestals is not affected during spraying; the parameters such as the start time, duration, interval time, and curing cycle of the spraying are set through the mobile phone software system to realize automatic remote release of control instructions, and realize fully automatic, intelligent, all-weather, fully wet, and standard curing control without omissions. In the winter construction environment, it can effectively insulate and moisturize the concrete, and carry out targeted maintenance according to the measured temperature and humidity data, breaking through the problems of inaccuracy, environmental pollution, low curing efficiency, and high energy consumption in the traditional winter curing method of concrete, and can eliminate the adverse effects of manual curing.

[0013] Compared with the prior art, the present invention has the following beneficial effects: Realize production automation based on CNC and automated production equipment, reduce production costs, and give full play to the production capacity advantages of CNC automation machinery; Based on the information-based intelligent factory production management system, a general management platform is established, and hardware equipment such as computers, surveillance cameras, and industrial Internet of Things sensors are used to collect equipment production data. With the help of artificial intelligence recognition technology, full monitoring of factory production safety management and safe digital production can be achieved, creating extensive social and economic benefits for enterprises; Robotic construction technology can automatically carry out construction according to design drawings, improve construction accuracy, replace manual labor for dangerous operations, ensure construction safety, improve construction efficiency, reduce the use of human resources, and reduce costs; The use of advanced equipment to replace conventional assembly formwork, the application of automated formwork systems and corresponding construction processes have not only improved construction efficiency, but also improved the quality of beam and slab prefabrication; It can automatically issue control instructions through time setting to achieve intelligent and fully automatic spraying maintenance, breaking through the problems of inaccuracy, environmental pollution, low maintenance efficiency and high energy consumption in traditional concrete maintenance methods, and can eliminate the adverse effects of manual maintenance; Breaking through the conventional management model, comprehensively utilizing big data, the Internet of Things, mobile Internet, artificial intelligence and other information, combined with the application of BIM technology, establishing an integrated information platform for construction management of "BIM+GIS", realizing the intelligent collection and processing of construction site data, digital management of archival materials, and automated, intelligent and information-based on-site management, greatly improving the management level of the beam factory. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1A process flow chart of an industrialized intelligent technology for prefabricated beam yards according to the present invention; Specific implementation plan

[0015] The present invention is further described below in conjunction with specific examples. The following embodiments are only used to illustrate the present invention, and are not used to limit the scope of protection of the present invention. In practical applications, improvements and adjustments made by those skilled in the art according to the present invention still fall within the scope of protection of the present invention.

[0016] In order to better illustrate the present invention, the present invention is described in detail below with reference to the accompanying drawings.

[0017] The present invention is a process flow chart of an industrialized intelligent technology method for prefabricated beam yard, such as Figure 1 As shown, the specific method includes the following steps: The first step is steel processing, forming and binding on the steel frame. The top plate, bottom plate and web steel bars are processed into steel skeletons on the steel frame, and then the skeleton is hoisted. When the steel skeleton is in place, the thickness of the protective layer must be padded with cement pads of the same grade as the beam body. The protective layer pads require no less than 4 per section and the spacing is not greater than 600mm. The position of the steel skeleton and embedded parts must be accurate, especially the fixation of embedded parts, to ensure that no displacement occurs during the concrete vibration process. The second step is the installation of corrugated pipes. The positive bending moment steel bundle of the prestressed beam uses metal corrugated pipes, and the negative bending moment uses plastic corrugated pipes. The metal corrugated pipe joints are butt-jointed with hot-melt joints. When installing the corrugated pipe, a well-shaped positioning rib is set every 25cm in the curved section and every 50cm in the straight section (the pipe marking is done on the frame in advance according to the drawing requirements) to ensure that the position of the prestressed channel meets the design requirements of the drawing. After the channel is formed, check each hole immediately. If blockage is found, it should be cleared in time. The third step is template installation. Template installation is divided into two steps: ① Template processing quality acceptance, quality tracking inspection during template processing, mainly checking whether the quality of template processing raw materials, welding quality, panel flatness, size, joints, reserved holes, etc. meet the design requirements; on-site acceptance, mainly checking template flatness, template size (including diagonal size) joint treatment, weld quality, connection bolt hole spacing, reserved holes, etc. After a single template is accepted, it will be tested in the back field. The test assembly mainly checks the quality of template joints, whether it is misaligned, the spacing of connection bolt holes, the internal dimensions of the structure, the verticality of the template, etc. ② The template is hoisted by a gantry and installed manually. The support system consists of pedestal embedded parts, fixed support rods, and tie rods, which are easy to install and disassemble. The fourth step is concrete pouring. Concrete pouring can be divided into two steps: ① Concrete pouring. Concrete is transported from the mixing station to the prefabricated beam yard by a concrete tank truck and placed in the hopper. The concrete hopper is lifted by a gantry crane for pouring. The concrete is poured in layers in the order of bottom plate, web plate, and top plate, and poured from one end of the beam to the other. Control of pouring time: Add high-efficiency slow-setting water-reducing agent to ensure that the concrete has sufficient initial setting time. During the pouring process, pay attention to prevent the inner mold from floating up and the accuracy of the position of the embedded parts. After pouring, the top plate of the beam body should be slurried for the second time and the surface should be roughened to prevent sinking cracks. ② Removal and extraction of the core mold. The upper and lower parts of the side mold of the core mold are connected by hinges, and the upper and lower rows of chords are connected to the middle horizontal crossbar. When removing the core mold, first knock out the internal pins of the core mold, and then use the winch to apply a horizontal external force to the crossbar. After the core mold is folded inward, it can be easily pulled out by the winch. The fifth step is concrete curing. The top plate is covered and sprayed to keep the concrete surface moist. The web plate is cured by an automatic spray device to ensure the curing quality of the beam. The conditions for water used for concrete curing are the same as those for concrete mixing. The curing time of concrete is not less than 7 days, and the age is 10 days. Before the concrete strength reaches 2.5MPa, the formwork shall not be removed. When the concrete strength reaches 2.5MPa, the inner and outer steel formworks shall be removed in time, and the geotextile shall be covered for timely curing; water injection curing is used in the box room.The sixth step is prestressing. The prestressing of the steel strands in the positive bending moment section can only be carried out when the concrete strength of the beam and slab reaches more than 90% and the concrete age is not less than 14d. The prestressed steel strands are tensioned by the method of bidirectional control of tension and elongation. The elongation value of each bundle of steel strands under initial tension, control tension and over-tension is calculated based on the strength, tension and elastic modulus of the steel strands. The seventh step is grouting and anchor sealing. Grouting and anchor sealing should be carried out in sequence: ① Grouting should be carried out first. Grouting must be completed within 48 hours after the prestressed tendons are tensioned. The grouting material should be checked before grouting the hole. The slurry mix ratio shall be tested by the project department and can be put into use after approval by the supervision engineer. Before grouting, the steel strands except the anchor shall be cut first. The grinding wheel cutter shall be used for cutting. Electric welding or oxygen cutting is prohibited. After cutting, the steel strands are exposed 3-5cm. After cutting, the gaps between the steel strands around the anchors are filled with cement mortar to avoid loss of grouting pressure due to grouting. The hole grouting machine adopts a piston-type grouting pump that can operate continuously. The hole grouting adopts a large-cycle intelligent grouting process. When grouting, the grouting pressure is controlled to be 0.5~0.7MPa, and the grouting should enter from the grouting hole at the lowest point. The grouting of the same hole is carried out continuously and completed at one time. ② Anchor sealing. After the prefabricated box girder is tensioned and grouting is completed, the anchor sealing operation is carried out in time. In this method, the anchor sealing of the prefabricated beam end is carried out before the prefabricated beam is hoisted into place. Check the roughening to ensure that the roughening is sufficient, and clean the roughening concrete joint surface. Install the anchor sealing section steel bars according to the requirements of the design drawings. The binding and welding of the steel bars must meet the requirements of the specifications and be firmly bound. After the steel bars are tied, install the template. The template for anchor sealing adopts a steel template. The anchor sealing end template is reinforced on the prefabricated beam with an adjustable top support or square wood plus wooden wedges. The joints of each template are glued with double-sided tape to prevent leakage. During the installation of the formwork, the focus is on checking whether the line shape is straight. After the self-inspection is qualified, it is reported to the supervisor for inspection. After the supervisor's inspection is qualified, the concrete of the anchor section is poured. The anchor section concrete uses C50 concrete, which is mixed centrally at the mixing station. When pouring concrete, due to the small space, an inserted vibrator is used for vibration. Be careful not to touch the steel bars and formwork during vibration. Step 8: Lifting and storage of beams and slabs. After the beams and slabs have reached the design strength after pouring and curing, and the tensioning and grouting are completed, the beams can be moved and stored. The lifting of the beams and slabs adopts the lifting method of supporting the bottom of the beams according to the design requirements, without lifting rings. During prefabrication, the movable bottom formwork required for the bottom of the cable is reserved at the bottom of the beam. The beams and slabs are lifted by the on-site gantry. After lifting the beam body in the beam making area, the gantry crane slowly moves to the beam storage area, and the beams and slabs are placed on the fulcrums at both ends of the beam storage pedestal to complete the lifting and storage of the beams and slabs. When the beams and slabs are stacked, the bottom pads are made of strip blocks and sleepers cast with C30 concrete. After each beam slab is hoisted into place, square wooden diagonal legs must be added on both sides to support it.

[0018] The invention discloses a semi-prefabricated construction technology method for a large cap beam, which has the following advantages: simplified design. When design standards, manuals and atlases are established, standard parts can be selected as much as possible to meet functional requirements like mechanical design, thereby simplifying the design; fast construction speed. Mature experience in the industry shows that the prefabricated assembly construction method saves more than 30% of the construction period compared with the on-site cast-in-place method; improved construction quality. The prefabricated beams produced by factory prefabrication have excellent equipment, perfect technology, skilled workers, and easy quality control, and the construction quality is greatly improved; improved construction environment. Most of the work is completed in the factory, and the on-site construction environment is greatly improved; improved working conditions. Due to the increased degree of mechanization and automation, the labor intensity of construction workers is reduced, and the working conditions can be improved; cost saving. The industrialized construction method saves costs compared with the traditional construction method, thereby bringing higher economic benefits.

[0019] The preferred embodiments of the present invention disclosed above are only used to help illustrate the present invention. The preferred embodiments do not describe all the details in detail, nor do they limit the invention to the specific implementation methods described. Obviously, many modifications and changes can be made according to the content of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the present invention, so that those skilled in the art can understand and use the present invention well. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. An industrialized intelligent technology method for prefabricated beam yard, characterized in that: It includes four core equipments: CNC rebar sawing and threading production line, CNC rebar bar shearing production line, CNC vertical rebar bending center and cap beam frame welding robot.

2. An industrialized intelligent technology method for prefabricated beam yard, characterized in that: The CNC steel bar sawing and threading production line adopts a streamlined design concept and has a multi-level raw material and finished product storage mechanism. It is mainly used for high-quality fixed-length sawing, transportation, storage and processing of straight steel bars, and each processing procedure forms a computer-controlled automatic processing line.

3. An industrialized intelligent technology method for prefabricated beam yard, characterized in that: The CNC steel bar shearing production line adopts advanced programmable CNC and PLC systems as the equipment control core, can set the cutting length arbitrarily and work continuously according to the set task category, and has high cutting accuracy.

4. An industrialized intelligent technology method for prefabricated beam yard, characterized in that: The CNC vertical steel bar bending center adopts a touch screen and a PLC control system, which can store up to hundreds of graphics and can be set up once and reused. The bending host is equipped with a dual CNC servo positioning system and can move simultaneously.

5. An industrialized intelligent technology method for prefabricated beam yard, characterized in that: The cap beam skeleton welding robot is mainly composed of a robot walking axis unit (ground rail), a six-axis linkage welding robot, a welding platform, an automatic clamp and an electrical operating system. The robot walking axis unit (ground rail) adopts gear rack transmission, and the automatic clamp adopts pneumatic / hydraulic method to drive the clamp.

6. The industrialized intelligent technology method for precast beam yard according to claim 1 is characterized in that: The automated formwork includes an automated integral hydraulic formwork (external formwork) and an automated box beam inner formwork system (inner formwork). The outer formwork consists of three parts: a formwork system, a hydraulic system and a walking system. The formwork system is similar to the structure of an ordinary steel formwork. The hydraulic system is attached and supported on the outer formwork. The walking system moves the formwork between different rows of pedestals in the prefabricated pedestal area through longitudinal tracks. The inner formwork consists of three parts: a formwork system, a hydraulic system and a traction system. The formwork system is similar to the structure of an ordinary steel formwork. The hydraulic system is attached and supported on the inner formwork. The traction system is mainly composed of a winch at the front end of the beam.

7. The industrialized intelligent technology method for precast beam yard according to claim 1 is characterized in that: The automatic spraying and steaming system adopts automatic control and wireless sensing technology, and its main components include: intelligent cloud controller, wireless network card, electromagnetic water valve, booster pump, pipeline system and automatic telescopic rotating nozzle.

Images