Prefabricated box girder production line

Abstract

The invention provides a prefabricated box girder production line, and belongs to the technical field of prefabricated box girder production. Comprising a steel bar machining area, a mold maintenance area, a concrete pouring area, a steam curing area, a natural curing area, a tensioning area and a beam storage area which are sequentially arranged. The reinforcement processing area is used for processing reinforcement frameworks; the mold maintenance area is used for adjusting the bottom mold conveying direction and storing and cleaning an inner mold. The concrete pouring area is used for pouring box girders; the steam curing area is used for performing steam curing on the box girder; the natural curing area is used for naturally curing the box girder; the tensioning area is used for installing and tensioning prestressed reinforcements of the box girder; the girder storage area is used for storing the machined box girders; foundation reinforcing structures are arranged at the bottoms of the mounting positions of at least part of production equipment in the production line area; by reasonably arranging all functional areas, the production efficiency is improved, meanwhile, dependence on foundation treatment is reduced, the early-stage cost is reduced, the inner mold storage area and the bottom mold rotation area are combined, and the site space utilization rate is increased.

Description

Technical Field

[0001] The invention belongs to the technical field of prefabricated box girder production, and in particular relates to a prefabricated box girder production line. Background Art

[0002] In the field of highway construction, prefabricated highway box girders are key components of the highway superstructure system, and their production progress has a decisive impact on the construction period of the entire project. In this context, the design of the prefabricated beam yard has become one of the core points in the project planning and implementation process.

[0003] At present, there are two typical schemes used in the design of precast beam yards.

[0004] The first solution is to set up a reciprocating bottom formwork in an area with good foundation conditions to carry out the production of prefabricated box girders. From the perspective of engineering practice, this solution, with its unique operation mode, can achieve high production efficiency of prefabricated box girders and provide strong guarantee for the advancement of the project progress. However, this solution has strict requirements on various indicators such as the bearing capacity and stability of the foundation. If the foundation conditions in the selected area cannot meet these requirements, in order to ensure the smooth progress of production operations and the quality and safety of prefabricated box girders, the foundation must be comprehensively and deeply treated. This will not only greatly increase the cost investment of engineering construction, but may also cause delays in the construction period, which will have an adverse impact on the smooth implementation of the entire project.

[0005] The second solution is to set up fixed positions for areas with poor foundation conditions to complete a series of processes such as casting and curing of prefabricated box girders, and then carry out hoisting operations after the box girders reach the specified strength. The outstanding advantage of this solution is that it can effectively reduce the workload of foundation treatment and, to a certain extent, reduce the cost and time consumption in the early stage of engineering preparation. However, it cannot be ignored that due to the relative lack of flexibility of the fixed position operation method, the connection efficiency between the various processes is low, making it difficult to effectively improve the production efficiency of prefabricated box girders and unable to meet the production capacity requirements of large-scale, high-efficiency highway construction projects for prefabricated box girders.

[0006] In view of the limitations of the above two solutions, the present invention proposes a prefabricated box girder production line to solve the contradiction between the production efficiency of prefabricated box girders and foundation conditions. Summary of the invention

[0007] The purpose of the present invention is to provide a prefabricated box girder production line to solve the above-mentioned problems existing in the prior art.

[0008] In order to achieve the above object, the prefabricated box girder production line of the present invention provides the following technical solutions: A prefabricated box girder production line, comprising: A steel bar processing area, wherein the steel bar processing area is used to process the steel bar skeleton of the prefabricated box beam; A mold maintenance area, which is used to adjust the bottom mold transportation direction and store and clean the inner mold; A concrete pouring area, wherein the concrete pouring area is used for pouring the box girder; A steam curing area, wherein the steam curing area is used to perform steam curing on the box girder; A natural curing area, wherein the natural curing area is used for natural curing of the box girder; A tensioning area, the tensioning area is used to install and tension the prestressed steel bars of the box girder; A beam storage area, wherein the beam storage area is used to store processed box beams; A foundation reinforcement structure is provided at the bottom of the installation position of at least part of the production equipment in the production line area to enhance the bearing capacity of the foundation.

[0009] As a further optimized technical solution, the foundation reinforcement structure includes: Prestressed high-strength concrete pipe piles, which are driven into the foundation; A crushed stone cushion layer, wherein the crushed stone cushion layer is arranged on the top of the prestressed high-strength concrete pipe pile; A basic support platform is arranged on top of the crushed stone cushion layer and is used to support the production equipment.

[0010] As a further optimized technical solution, a connecting piece is provided on the top of the prestressed high-strength concrete pipe pile, and the connecting piece extends through the gravel cushion layer and is integrally cast inside the foundation support platform.

[0011] As a further optimized technical solution, the connecting piece includes an integrally arranged diffusion section and a core filling section, the core filling section is used to be fixedly connected to the top of the prestressed high-strength concrete pipe pile and pass through the gravel cushion layer, and the diffusion section gradually decreases in width from top to bottom.

[0012] As a further optimized technical solution, the mold maintenance area is provided with an internal mold maintenance vehicle and a bottom mold transport vehicle. The internal mold maintenance vehicle is used for demolding, cleaning and transporting the inner mold, and the bottom mold transport vehicle is used for carrying and adjusting the bottom mold transport direction.

[0013] As a further optimized technical solution, prefabricated tracks are arranged through the mold maintenance area, concrete pouring area, steam curing area, natural curing area and tensioning area, and the bottom mold transport vehicle runs along the prefabricated tracks.

[0014] As a further optimized technical solution, the bottom mold transport vehicle includes a vehicle body, and a bottom mold is arranged on the top of the vehicle body.

[0015] As a further optimized technical solution, the internal mold maintenance vehicle includes: A support unit, the support unit having a support frame and transverse wheels, and used for receiving, supporting and transversely transporting the inner mold; A pulling unit, the pulling unit being arranged at one end of the supporting unit and being used for pulling the inner mold onto the supporting unit; A cleaning unit is used to clean the outer surface of the inner mold.

[0016] As a further optimized technical solution, the cleaning unit includes a first cleaning mechanism for cleaning the bottom wall of the inner mold and a second cleaning mechanism for cleaning the part other than the bottom wall. The first cleaning mechanism is arranged at one end of the support unit away from the pulling unit, and the second cleaning mechanism can move back and forth in a straight line along the top of the support unit to clean the inner mold.

[0017] As a further optimized technical solution, the first cleaning mechanism includes a cleaning roller brush and a lifting and adjusting structure, the lifting and adjusting structure is fixedly arranged on the supporting unit, and the cleaning roller brush is rotatably arranged on the top of the lifting and adjusting structure; The second cleaning mechanism includes a movable frame and a cleaning roller brush. The movable frame is used to move along the top of the supporting frame. The cleaning roller brush is arranged on the inner side of the movable frame and is used to clean the top wall, top chamfer and side wall of the inner mold respectively.

[0018] Beneficial effects: First, the present invention sets a foundation reinforcement structure at the bottom of the installation position of at least part of the production equipment in the production line area. The structure is composed of prestressed high-strength concrete pipe piles, a crushed stone cushion layer and a foundation support platform. Through this combination, the weight of the production equipment and the prefabricated box beams can be evenly dispersed into the foundation, greatly enhancing the bearing capacity of the foundation; this enables the production line to operate stably when facing sites with different geological conditions, effectively reducing the production risks caused by limitations of foundation conditions.

[0019] Second, the traditional prefabricated box girder production plan has high requirements for foundation conditions. When the foundation conditions are not met, large-scale foundation treatment work is often required, which not only consumes a lot of money but also prolongs the construction period. The production line of the present invention has a strong foundation adaptability, which reduces the dependence on foundation treatment to a certain extent, reduces the cost investment in the early engineering preparation stage, and also avoids the construction delay caused by foundation treatment, providing a strong guarantee for the smooth progress of the project.

[0020] Third, the production line scientifically and rationally plans each functional area, and arranges the steel bar processing area, mold maintenance area, concrete pouring area, steam curing area, natural curing area, tensioning area and beam storage area in sequence, forming a coherent and efficient production process; each production link is closely connected, which greatly reduces the waiting time between processes and the time loss of material transportation, allowing prefabricated box girders to circulate quickly in each production stage, thereby achieving a significant improvement in production efficiency and fully meeting the high-capacity demand for prefabricated box girders in large-scale highway construction projects.

[0021] Fourth, in traditional prefabricated box girder production lines, it is usually necessary to arrange separate inner mold storage areas and bottom mold rotation areas, which are respectively used to store inner molds and adjust the transportation direction of the bottom molds. In the present invention, an internal mold maintenance vehicle is provided. The function of the internal mold maintenance vehicle to adjust the position of the inner mold horizontally can effectively avoid the bottom mold transport vehicle that adjusts the transportation direction of the bottom mold. Therefore, there is no need to separately set up independent inner mold storage areas and bottom mold rotation areas. The inner mold storage area and the bottom mold rotation area are merged into one mold maintenance area, thereby reducing the floor space of the production area, improving the utilization rate of the site space, reducing the site construction and operation costs, making the prefabricated box girder production site planning more compact and reasonable, enhancing the economy and flexibility of the overall production system, and optimizing the site layout. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The drawings constituting a part of the present application are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. Among them: Figure 1 A top view of a prefabricated box girder production line according to an embodiment of the present invention; Figure 2 A top view of a mold maintenance area and a concrete pouring area according to an embodiment of the present invention; Figure 3 A schematic diagram of an application state of a foundation reinforcement structure according to an embodiment of the present invention; Figure 4 A schematic diagram of another application state of a foundation reinforcement structure according to an embodiment of the present invention; Figure 5 This is a schematic structural diagram of a pouring station in a concrete pouring area according to an embodiment of the present invention; Figure 6 This is a schematic diagram of inner mold demoulding according to an embodiment of the present invention; Figure 7 A schematic elevation diagram of a beam storage area from one perspective of an embodiment of the present invention; Figure 8 A schematic elevation diagram of a beam storage area from another perspective of an embodiment of the present invention; Fig. 9A schematic diagram of the working state of a steam curing area according to an embodiment of the present invention; Fig.10 A schematic elevation diagram of a concrete pouring area according to an embodiment of the present invention; Fig.11 This is a schematic diagram of the overall structure of an internal mold maintenance vehicle according to an embodiment of the present invention; Fig.12 for Fig.11 The enlarged structural diagram of part A in the middle; Fig.13 A schematic diagram of a mobile frame structure according to an embodiment of the present invention; Fig.14 A schematic diagram of cleaning the top wall of an inner mold according to an embodiment of the present invention; Fig.15 A schematic diagram of cleaning the inner mold side wall according to an embodiment of the present invention; Fig.16 This is a schematic diagram of the inner mold top chamfer cleaning according to an embodiment of the present invention.

[0023] In the figure: 100, steel bar processing area; 110, intelligent truss crane; 120, top plate processing equipment; 130, adjustment and unloading equipment; 140, welding equipment; 150, bending equipment; 160, steel bar unloading area; 200, mold maintenance area; 210, internal mold maintenance vehicle; 211, support frame; 212, transverse wheel; 213, pulling unit; 214, traction rope; 215, cleaning roller brush; 216, lifting and adjusting structure; 217, mobile frame; 218, telescopic structure; 220, bottom mold transport vehicle; 230, inner mold; 240, bottom mold; 241, lifting device; 300, concrete pouring area; 310, material distribution trolley; 320, side mold; 400, steam Steam curing area; 410, steam curing shed; 420, spray pipeline; 430, steam pipeline; 440, concrete mixing plant; 450, transport track; 460, torpedo tank; 500, natural curing area; 600, tensioning area; 610, tensioning equipment; 700, beam storage area; 710, beam storage pedestal; 720, gantry crane; 721, running track; 730, beam outlet channel; 800, foundation reinforcement structure; 810, prestressed high-strength concrete pipe piles; 820, crushed stone cushion; 830, foundation support platform; 840, connector; 900, precast track; 910, production track; 920, rotary track; 921, lateral moving section; 922, lateral moving equipment. DETAILED DESCRIPTION

[0024] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention belong to the scope of protection of the present invention.

[0025] In the description of the present invention, the terms "longitudinal", "lateral", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and do not require that the present invention must be constructed and operated in a specific orientation. Therefore, they should not be understood as limitations on the present invention. The terms "connected" and "connected" used in the present invention should be understood in a broad sense. For example, they can be fixed connections or detachable connections; they can be directly connected or indirectly connected through intermediate components. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0026] The present invention will be described in detail below with reference to the accompanying drawings and in combination with embodiments. It should be noted that the embodiments and features in the embodiments of the present invention can be combined with each other without conflict.

[0027] The shapes and sizes of the components in the drawings do not reflect the actual proportions of the products, and are only intended to illustrate the contents of the present invention.

[0028] The present invention provides a prefabricated box girder production line, which improves production efficiency by reasonably arranging various functional areas, closely connecting production links, reducing process waiting time and material transfer time; at the same time, it reduces dependence on foundation treatment, reduces initial costs and the risk of construction delays, and also combines the inner mold storage area and the bottom mold rotation area, reducing the production area footprint and improving site space utilization. Please refer to the following examples for specific technical solutions: Example 1 like Figure 1-16 For details, please refer to Figure 1 The prefabricated box beam production line includes a steel bar processing area 100, a mold maintenance area 200, a concrete pouring area 300, a steam curing area 400, a natural curing area 500, a tensioning area 600 and a beam storage area 700 arranged in sequence. Among them, a prefabricated track 900 is set through the mold maintenance area 200, the concrete pouring area 300, the steam curing area 400, the natural curing area 500 and the tensioning area 600 to transport the processing equipment in the above-mentioned areas.

[0029] The steel bar processing area 100 is used to process the steel bar skeleton of the prefabricated box girder. In this area, professional steel bar processing equipment is arranged in an orderly manner. These mature steel bar processing equipment usually include intelligent truss cranes 110, top plate processing equipment 120, adjustment and unloading equipment 130, welding equipment 140, bending equipment 150, etc. They work together to accurately straighten, bend, cut and assemble the steel bars, and finally make the steel bars into a steel bar skeleton that meets the design requirements, providing a solid structural foundation for the subsequent box girder casting. The detailed processing method of the specific steel bar skeleton can be referred to the Chinese invention patent application with publication number CN118682045A, which will not be repeated here. A steel bar unloading area 160 is provided at one end of the steel bar processing area 100 away from the mold maintenance area 200, which is used to receive and transport raw materials into the production line. In this way, the steel bar transport vehicles transport the steel bars to the steel bar unloading area 160, and the intelligent gantry crane 110 lifts them to the locations of various processing equipment, avoiding heavy-load vehicles from entering the steel bar processing area 100, reducing the requirements for foundation treatment in the steel bar processing area 100 during the construction of the production line, and reducing the construction cost of the production line.

[0030] like Figure 1 , Figure 2 As shown, the mold maintenance area 200 is used to adjust the transportation direction of the bottom mold 240 and store and clean the inner mold 230. Specifically, the mold maintenance area 200 is provided with an intelligent truss crane 110, an internal mold maintenance vehicle 210 and a bottom mold transport vehicle 220. The internal mold maintenance vehicle 210 is used to demold the inner mold 230 and clean and transport the inner mold 230, and the bottom mold transport vehicle 220 is used to carry and adjust the transportation direction of the bottom mold 240.

[0031] like Fig.11 As shown, the bottom mold transport vehicle 220 includes a vehicle body, which can run longitudinally along the prefabricated track 900, and a bottom mold 240 is arranged on the top of the vehicle body. The operation of the vehicle body can be intelligently controlled by existing programming. Specifically, after the vehicle body receives the transfer instruction, the bottom mold transport vehicle 220 starts and accurately transports the bottom mold 240 to the designated position.

[0032] The internal mold maintenance vehicle 210 includes a supporting unit, a pulling unit 213 and a cleaning unit.

[0033] The support unit has a support frame 211 and a transverse wheel 212, which are used to receive, support and transversely transport the inner mold 230. Specifically, the support frame 211 is a frame structure that is welded with steel pipes and is generally in the shape of a rectangular parallelepiped. A widening structure is provided on both sides of the top to facilitate the placement of the inner mold 230 while allowing some cleaning units of the cleaning unit to move along the top of the support frame 211 for cleaning. The transverse wheel 212 is provided at the bottom of the support frame 211 and the rolling direction is perpendicular to the length extension direction of the inner mold 230, so that the support unit carries the inner mold 230 and moves transversely along the width direction in the mold maintenance area 200.

[0034] The pulling unit 213 is disposed at one end of the support frame 211 and is used to pull the inner mold 230 onto the support unit. In this embodiment, the pulling unit 213 is a winch, which is fixedly mounted at one end of the support frame 211 away from the concrete pouring area 300. The winch has a pulling rope 214 for pulling the inner mold 230. The pulling rope 214 has sufficient tensile strength to withstand the pulling demand of the inner mold 230.

[0035] The cleaning unit is used to clean the outer surface of the inner mold 230 .

[0036] Specifically, the cleaning unit includes a first cleaning mechanism for cleaning the bottom wall of the inner mold 230 and a second cleaning mechanism for cleaning the part other than the bottom wall. The first cleaning mechanism is arranged at one end of the support unit away from the pulling unit 213, and the second cleaning mechanism can move back and forth in a straight line along the top of the support unit to clean the inner mold 230.

[0037] like Fig.12 As shown, the first cleaning mechanism is arranged at one end of the support frame 211 close to the concrete pouring area 300, and has a cleaning roller brush 215 and a lifting adjustment structure 216. The lifting adjustment structure 216 is fixedly arranged on the support frame 211, and the cleaning roller brush 215 is rotatably arranged on the top of the lifting adjustment structure 216 to clean the bottom wall of the inner mold 230 pulled and moved by the pulling unit 213 from the top of the cleaning roller brush 215, that is, in the process of the pulling unit 213 pulling the moving inner mold 230 to the support frame 211, the first cleaning mechanism is activated, and the bottom wall of the inner mold 230 is completely cleaned after the inner mold 230 is completely pulled onto the support frame 211. The purpose of setting the lifting adjustment structure 216 is to make the cleaning roller brush 215 suitable for the inner mold 230 with uneven bottom wall height.

[0038] like Fig.13 , Fig.14 , Fig.15 , Fig.16As shown, the second cleaning mechanism includes a moving frame 217 and a cleaning roller brush 215. The moving frame 217 is a frame-type structure, and has a channel in the middle whose size is larger than the cross-sectional size of the inner mold 230. The moving frame 217 is used to move back and forth linearly along the top of the supporting frame 211. During the movement, the supporting frame 211 avoids the inner mold 230 through the channel. The cleaning roller brush 215 is arranged on the inner side of the channel of the moving frame 217, and specifically, the cleaning roller brush 215 is respectively arranged on the top wall, top chamfer and side wall of the inner mold 230 to clean the top wall, top chamfer and side wall of the inner mold 230 respectively.

[0039] Specifically, all cleaning roller brushes 215 in the second cleaning mechanism are installed on the movable frame 217 through a telescopic structure 218. The telescopic structure 218 can use a common electric-controlled lifting device or a hydraulic lifting mechanism, which is used to adjust the cleaning roller brushes 215 at each position to move away from or close to the inner mold 230, thereby ensuring the cleaning effect and making the second cleaning mechanism applicable to inner molds 230 of different sizes.

[0040] All the above cleaning roller brushes 215 have the same material and structure. In addition, the length of each position is adaptively adjusted according to the position of the inner mold 230 to be cleaned. The bristles can be made of wear-resistant and elastic nylon material, which can effectively clean the top wall and avoid damage to the mold.

[0041] In this way, after the inner mold 230 is pulled onto the supporting frame 211 by the pulling unit 213, the inner mold 230 is cleaned by the cleaning unit, and then the movable frame 217 can carry the inner mold 230 and move along the width direction of the mold maintenance area 200, which can provide space for the turning of the bottom mold transport vehicle 220 and move the inner mold 230 to other workstations, thereby improving the turnover rate and usage frequency of the inner mold 230.

[0042] During the use of the internal mold maintenance vehicle 210, since the internal mold maintenance vehicle 210 has the function of adjusting the position of the inner mold 230 by lateral movement, compared with the traditional separate arrangement of the inner mold storage area and the bottom mold rotation area, the technical solution of the present invention only needs to set up one mold maintenance area 200, which can simultaneously realize the storage of the inner mold 230 and the adjustment of the transportation direction of the bottom mold 240, effectively reducing the floor space occupied by the production area and improving the utilization rate of the site space.

[0043] like Figure 2 , Figure 5As shown, the concrete pouring area 300 is used to pour the box girder. There is professional concrete pouring equipment in the concrete pouring area 300, and the pouring equipment includes a material distribution trolley 310 and a side mold 320 of the box girder. In this area, the inner mold 230, the bottom mold 240 and the side mold 320 are molded together, and then the material distribution trolley 310 is used to distribute and pour concrete. During the pouring process, the operator controls the pouring speed and pouring amount of concrete according to the design requirements of the prefabricated box girder to ensure that the concrete is evenly filled into all parts of the mold. At the same time, in order to ensure the compactness of the concrete, a vibrating device is used to vibrate the concrete. The vibrating device uses high-frequency vibration to discharge the bubbles in the concrete and improve the compactness and strength of the concrete.

[0044] In addition, in the present invention, in order to facilitate the use of concrete, a concrete mixing station 440 is provided in the steam curing area 400, and a transport track 450 for transporting a torpedo tank 460 is arranged above the steam curing area 400. Specifically, the mixed concrete is transported to the material distribution trolley 310 through the torpedo tank 460, and then the material distribution trolley 310 performs subsequent pouring work. For details, please refer to Figure 1 , Fig.10 .

[0045] The cast box beam is then transferred to the steam curing area 400. Figure 1 , Fig. 9 As shown, the steam curing area 400 is used to steam-cure the box girder. A special steam curing shed 410, a steam generating device, and a temperature and humidity control system are set in the steam curing area 400. When the box girder enters the steam curing shed 410 of the steam curing area 400, the spray pipeline 420 and the steam pipeline 430 of the steam generating device start to work, and transport high-temperature steam to the curing area, so that the temperature and humidity in the curing area are rapidly increased to the set value. During the curing process, the temperature and humidity control system monitors the temperature and humidity changes in the curing area in real time, and automatically adjusts the steam supply and ventilation volume according to the monitoring data to ensure the stability of the curing environment. Through steam curing, the hydration reaction of concrete can be accelerated, the early strength of concrete can be improved, and the curing time can be shortened.

[0046] After the steam curing reaches the specified time, the box girder is transferred to the natural curing area 500 for further natural curing. The natural curing area 500 is equipped with sunshade, rain protection and other facilities to provide a suitable natural curing environment for the box girder. During the natural curing process, the concrete continues to undergo hydration reaction and its strength gradually increases. The operator regularly tests the strength of the box girder to ensure that the strength of the box girder meets the tension strength requirements.

[0047] The box girder that has completed maintenance is transported to the tensioning area 600. The tensioning area 600 is used to install and tension the prestressed steel bars of the box girder. In the tensioning area 600, professional tensioning equipment 610 installs and tensions the prestressed steel bars of the box girder according to the design requirements. First, the operator inserts the prestressed steel bars into the reserved holes of the box girder and fixes both ends of the steel bars. Then, the tensioning equipment 610 is used to apply tension to the prestressed steel bars to cause elastic deformation of the steel bars, thereby applying prestress to the box girder. During the tensioning process, the tensioning stress and elongation are strictly controlled to ensure that the application of prestress meets the design requirements. Through tensioning operations, the bearing capacity and crack resistance of the box girder can be improved.

[0048] The box beams that have completed the tensioning operation are finally transferred to the beam storage area 700 for storage. Figure 1 , Figure 7 , Figure 8 As shown, the beam storage area 700 is used to store the processed box beams. A gantry crane 720 and a beam storage pedestal 710 are provided in the beam storage area 700, wherein the beam storage pedestal 710 is used to support the box beams, and the box beams are placed on the beam storage pedestal 710 in a certain order and spacing. The gantry crane 720 is used to transport the box beams. During the beam storage process, the box beams are regularly inspected and maintained to ensure the quality and safety of the box beams.

[0049] The prefabricated track 900 in the above-mentioned production line includes a production track 910 and a rotary track 920. The production track 910 crosses the processing stations in various functional areas, and the rotary track 920 avoids the processing stations for the rotation of the equipment. Specifically, lateral moving sections 921 are arranged at both ends of the rotary track 920, and lateral moving equipment 922 (such as a lateral moving shuttle bus) is provided on the lateral moving section 921 to assist the processing equipment in changing the direction of transportation.

[0050] In order to enhance the bearing capacity of the foundation in the above-mentioned production line area, a foundation reinforcement structure 800 is provided at the bottom of the installation location of at least part of the production equipment.

[0051] In this embodiment, the foundation reinforcement structure 800 is arranged specifically at the positions of the prefabricated track 900 , the tensioning device 610 , and the running track 721 of the gantry crane 720 .

[0052] like Figure 3 , Figure 4 As shown, the foundation reinforcement structure 800 includes a prestressed high-strength concrete pile 810 (Prestressed High-strength Concrete Pile, referred to as PHC pile), a crushed stone cushion layer 820 and a foundation support platform 830.

[0053] Prestressed high-strength concrete pipe piles 810 are driven into the foundation. Through the friction between the pile body and the surrounding soil and the end resistance of the pile end, the weight of the upper equipment and box beams is transferred to the deep stable soil layer, which can quickly improve the bearing capacity and stability of the soft foundation and reduce the workload of treating the soft foundation. The crushed stone cushion layer 820 is laid on the top of the prestressed high-strength concrete pipe piles 810. It can evenly disperse the stress transmitted by the prestressed high-strength concrete pipe piles 810, and at the same time play a role in drainage and preventing foundation soil disturbance. The foundation support platform 830 is set on the top of the crushed stone cushion layer 820. It adopts a reinforced concrete structure with sufficient strength and rigidity. It can firmly support the production equipment and ensure the stability of the equipment during operation.

[0054] In addition, a connector 840 is provided at the top of the prestressed high-strength concrete pipe pile 810, and the connector 840 extends through the gravel cushion layer 820 and is integrally cast inside the foundation support platform 830. The connector 840 includes an integrally arranged diffusion section and a core-filling section, the core-filling section is used to be fixedly connected to the top of the prestressed high-strength concrete pipe pile 810 and passes through the gravel cushion layer 820, and the diffusion section gradually decreases in width from top to bottom. This design can effectively enhance the connection strength between the prestressed high-strength concrete pipe pile 810 and the foundation support platform 830, and prevent loosening and displacement during the operation of the equipment.

[0055] The specific workflow of the present invention is as follows: In the first step, the steel bar transport vehicle transports the steel bars to the steel bar unloading area 160, and then the intelligent truss crane 110 in the steel bar processing area 100 hoists the steel bars to the positions of various processing equipment for processing, and finally processes the steel bars into the steel bar skeleton of the box girder.

[0056] In the second step, after the steel frame is processed, it is hoisted by the intelligent truss crane 110 to the bottom mold 240 of the mobile bottom mold transport vehicle 220. The bottom mold transport vehicle 220 moves from the mold maintenance area 200 along the production track 910 to the concrete pouring area 300. At the same time, the inner mold 230 is transferred to the concrete pouring area 300. In the concrete pouring area 300, the side mold 320 and the bottom mold 240 are completed.

[0057] In the third step, concrete is prepared by the concrete mixing station 440, transported to the top of the concrete pouring area 300 by the torpedo tank 460, and unloaded to the distribution trolley 310. The distribution trolley 310 then performs the concrete pouring operation, and simultaneously performs the concrete vibrating operation during the pouring process until the concrete pouring process is completed.

[0058] The fourth step is to allow the concrete to stand still until the box girder concrete has finally set after the concrete pouring is completed.

[0059] Step 5: After the concrete is finally set, the inner mold 230 is controlled to be retracted inwards, and the lifting device 241 on the bottom mold 240 is raised to lift the inner mold 230. Please refer to Figure 6 Then, the inner mold 230 is pulled out of the box beam by the pulling unit 213 of the internal mold maintenance vehicle 210 to complete demoulding.

[0060] Step 6. After the box beam is demoulded, the bottom mold transport vehicle 220 carries the prefabricated box beam along the production track 910 to the steam curing area 400, and steam cures the prefabricated box beam in the steam curing shed 410.

[0061] Step 7: After steam curing is completed, the bottom mold transport vehicle 220 carries the prefabricated box beam along the production track 910 to the natural curing area 500 for outdoor spray curing to the tensile strength.

[0062] Step 8. After the natural curing is completed, the bottom mold transport vehicle 220 carries the prefabricated box beam along the production track 910 to the tensioning area 600, and performs prestressing on the prefabricated box beam and prestressing.

[0063] In the ninth step, after the tensioning is completed, the gantry crane 720 lifts the prefabricated box beam from the bottom mold transport vehicle 220 and moves it horizontally to the beam storage area 700 for beam storage, and performs grouting of the prefabricated box beam in the beam storage area 700.

[0064] In the tenth step, after the prefabricated box girder is lifted, the bottom mold transport vehicle 220 returns to the mold maintenance area 200 through the revolving track 920, and returns to the production track 910 with the assistance of the transverse moving device 922, and then continues to receive the prefabricated box girder steel bar skeleton from the steel bar processing area 100 to carry out the next production cycle.

[0065] In the eleventh step, after the grouting and curing of the prefabricated box girder is completed, the prefabricated box girder is lifted from the beam storage pedestal 710 by the gantry crane 720 and moved horizontally to the beam outlet channel 730, and then transported to the site for installation by the beam transport vehicle.

[0066] It should be understood that the above description is merely exemplary and the embodiments of the present application do not limit this.

[0067] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention are within the scope of protection of the pending claims of the present invention.

Claims

1. A prefabricated box girder production line, characterized in that: Includes the following arranged in sequence: A steel bar processing area (100), wherein the steel bar processing area (100) is used to process a steel bar skeleton of a prefabricated box girder; A mold maintenance area (200), wherein the mold maintenance area (200) is used to adjust the transport direction of the bottom mold (240) and to store and clean the inner mold (230); A concrete pouring area (300), wherein the concrete pouring area (300) is used for pouring a box beam; A steam curing area (400), wherein the steam curing area (400) is used to perform steam curing on the box girder; A natural curing area (500), wherein the natural curing area (500) is used to perform natural curing on the box girder; A tensioning area (600), wherein the tensioning area (600) is used to install and tension the prestressed steel bars of the box beam; A beam storage area (700), wherein the beam storage area (700) is used to store processed box beams; A foundation reinforcement structure (800) is provided at the bottom of the installation position of at least part of the production equipment in the production line area to enhance the bearing capacity of the foundation.

2. The prefabricated box girder production line according to claim 1, characterized in that: The foundation reinforcement structure (800) comprises: Prestressed high-strength concrete pipe piles (810), wherein the prestressed high-strength concrete pipe piles (810) are driven into the foundation; A crushed stone cushion layer (820), wherein the crushed stone cushion layer (820) is arranged on top of the prestressed high-strength concrete pipe pile (810); A basic support platform (830) is provided on top of the crushed stone cushion layer (820) and is used to support the production equipment.

3. The prefabricated box girder production line according to claim 2, characterized in that: A connecting piece (840) is provided on the top of the prestressed high-strength concrete pipe pile (810), and the connecting piece (840) extends through the gravel cushion layer (820) and is integrally cast inside the foundation support platform (830).

4. The prefabricated box girder production line according to claim 3, characterized in that: The connecting piece (840) comprises a diffuser section and a core-filling section which are integrally arranged; the core-filling section is used to be fixedly connected to the top of the prestressed high-strength concrete pipe pile (810) and to pass through the gravel cushion layer (820); and the diffuser section gradually decreases in width from top to bottom.

5. The prefabricated box girder production line according to claim 1, characterized in that: The mold maintenance area (200) is provided with an internal mold maintenance vehicle (210) and a bottom mold transport vehicle (220). The internal mold maintenance vehicle (210) is used for demoulding the inner mold (230) and cleaning and transporting the inner mold (230), and the bottom mold transport vehicle (220) is used for carrying and adjusting the transport direction of the bottom mold (240).

6. The prefabricated box girder production line according to claim 5, characterized in that: A prefabricated track (900) is provided through the mold maintenance area (200), the concrete pouring area (300), the steam curing area (400), the natural curing area (500) and the tensioning area (600), and the bottom mold transport vehicle (220) runs along the prefabricated track (900).

7. The prefabricated box girder production line according to claim 6, characterized in that: The bottom mold transport vehicle (220) comprises a vehicle body, and a bottom mold (240) is arranged on the top of the vehicle body.

8. The prefabricated box beam production line according to claim 5, characterized in that: The internal mold maintenance vehicle (210) comprises: A support unit, the support unit comprising a support frame (211) and a transverse shifting wheel (212), and being used for receiving, supporting and transversely transporting the inner mold (230); A pulling unit (213), the pulling unit (213) being arranged at one end of the supporting unit and being used to pull the inner mold (230) onto the supporting unit; A cleaning unit, wherein the cleaning unit is used to clean the outer surface of the inner mold (230).

9. The prefabricated box girder production line according to claim 8, characterized in that: The cleaning unit comprises a first cleaning mechanism for cleaning the bottom wall of the inner mold (230) and a second cleaning mechanism for cleaning the portion other than the bottom wall, wherein the first cleaning mechanism is arranged at an end of the support unit away from the pulling unit (213), and the second cleaning mechanism can reciprocate linearly along the top of the support unit to clean the inner mold (230).

10. The prefabricated box beam production line according to claim 9, characterized in that: The first cleaning mechanism comprises a cleaning roller brush (215) and a lifting and adjusting structure (216); the lifting and adjusting structure (216) is fixedly arranged on the support unit, and the cleaning roller brush (215) is rotatably arranged on the top of the lifting and adjusting structure (216); The second cleaning mechanism comprises a movable frame (217) and a cleaning roller brush (215); the movable frame (217) is used to move along the top of the supporting frame (211); and the cleaning roller brush (215) is arranged on the inner side of the movable frame (217) and is used to clean the top wall, top chamfer and side wall of the inner mold (230).

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