A precast box girder production line

Abstract

The present invention provides a precast box girder production line, belonging to the technical field of precast box girder production; it includes a steel bar processing 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 arranged in sequence; the steel bar processing area is used for processing steel bar skeletons; the mold maintenance area is used for adjusting the transportation direction of the bottom mold and storing and cleaning the inner mold; the concrete pouring area is used for pouring box girders; the steam curing area is used for steam curing the box girders; the natural curing area is used for natural curing the box girders; the tensioning area is used for installing and tensioning the prestressed steel bars of the box girders; the beam storage area is used for storing the processed box girders; a foundation strengthening structure is provided at the bottom of the installation positions of at least some production equipment within the production line area; by reasonably arranging each functional area, the present invention improves the production efficiency, reduces the dependence on foundation treatment, reduces the upfront cost, and also combines the inner mold storage area and the bottom mold rotation area to improve the utilization rate of the site space.

Description

Technical Field

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

[0002] In the field of highway engineering construction, precast highway box girders, as a key component of the upper structure system of highways, have a decisive impact on the construction period of the entire project. Against this background, the design of precast beam yards has become one of the core points in the process of project planning and implementation.

[0003] Currently, two typical schemes are mainly adopted in the design of precast beam yards.

[0004] The first scheme is to set up a reciprocating moving bottom formwork in an area with good foundation conditions for the production operation of precast box girders. Judging from the engineering practice effect, this scheme, with its unique operation mode, can achieve a relatively high production efficiency of precast box girders, providing a strong guarantee for the progress of the project. However, this scheme has strict requirements for various indicators such as the bearing capacity and stability of the foundation. If the foundation conditions of the selected area cannot meet these requirements, in order to ensure the smooth progress of the production operation and the quality and safety of precast box girders, it is necessary to conduct a comprehensive and in-depth treatment of the foundation. This will not only greatly increase the cost investment in the project construction but also may lead to a delay in the construction period, having an adverse impact on the smooth implementation of the entire project.

[0005] The second scheme is for areas with poor foundation conditions, and a fixed production position is set up to complete a series of processes such as the casting and curing of precast box girders, and the lifting operation is carried out after the box girder reaches the specified strength. The prominent advantage of this scheme is that it can effectively reduce the workload of foundation treatment, reducing the cost and time consumption in the early project preparation stage to a certain extent. However, it cannot be ignored that due to the relatively inflexible operation mode of the fixed production position and the low connection efficiency between each process, the production efficiency of precast box girders is difficult to be effectively improved, and it cannot meet the production capacity requirements of precast box girders for large-scale and high-efficiency highway construction projects.

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

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

[0008] In order to achieve the above purpose, the precast box girder production line of the invention provides the following technical solutions:

[0009] A precast box girder production line includes the following arranged in sequence:

[0010] The steel bar processing area is used for processing the steel bar skeletons of precast box girders;

[0011] The mold maintenance area is used for adjusting the transportation direction of the bottom mold and storing and cleaning the internal mold;

[0012] The concrete pouring area is used for pouring box girders;

[0013] The steam curing area is used for steam curing box girders;

[0014] The natural curing area is used for natural curing box girders;

[0015] The tensioning area is used for installing and tensioning the prestressed steel bars of box girders;

[0016] The beam storage area is used for storing the processed box girders;

[0017] At the bottom of the installation positions of at least some of the production equipment in the production line area, a foundation strengthening structure is provided to enhance the bearing capacity of the foundation.

[0018] As a further optimized technical solution, the foundation strengthening structure includes:

[0019] Prestressed high-strength concrete pipe piles, which are driven into the foundation;

[0020] A gravel cushion layer, which is arranged on the top of the prestressed high-strength concrete pipe piles;

[0021] A foundation support platform, which is arranged on the top of the gravel cushion layer and is used for supporting production equipment.

[0022] As a further optimized technical solution, a connecting piece is arranged 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.

[0023] As a further optimized technical solution, the connecting piece includes a diffusion section and a core filling section which are integrally arranged. The core filling section is used for fixedly connecting with the top of the prestressed high-strength concrete pipe pile and passing through the gravel cushion layer, and the width of the diffusion section gradually decreases from top to bottom.

[0024] As a further optimized technical solution, an internal mold maintenance vehicle and a bottom mold transport vehicle are arranged in the mold maintenance area. The internal mold maintenance vehicle is used for demolding and cleaning and transporting the internal mold, and the bottom mold transport vehicle is used for carrying and adjusting the transportation direction of the bottom mold.

[0025] As a further optimized technical solution, precast tracks are arranged through the mold maintenance area, the concrete pouring area, the steam curing area, the natural curing area and the tensioning area, and the bottom mold transport vehicle runs along the precast tracks.

[0026] 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.

[0027] As a further optimized technical solution, the internal mold maintenance vehicle includes:

[0028] A support unit, which has a support frame body and transverse moving wheels for receiving, supporting and laterally transporting the internal mold;

[0029] A pulling unit, which is arranged at one end of the support unit for pulling the internal mold onto the support unit;

[0030] A cleaning unit for cleaning the outer surface of the internal mold.

[0031] As a further optimized technical solution, the cleaning unit includes a first cleaning mechanism for cleaning the bottom wall of the internal mold and a second cleaning mechanism for cleaning the parts 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 linearly back and forth along the top of the support unit to clean the internal mold.

[0032] As a further optimized technical solution, the first cleaning mechanism includes a cleaning brush roller and a lifting adjustment structure. The lifting adjustment structure is fixedly arranged on the support unit, and the cleaning brush roller is rotatably arranged on the top of the lifting adjustment structure;

[0033] The second cleaning mechanism includes a moving frame body and a cleaning brush roller. The moving frame body is used to move along the top of the support frame body, and the cleaning brush rollers are arranged inside the moving frame body respectively for cleaning the top wall, the top chamfer and the side wall of the internal mold.

[0034] Beneficial effects:

[0035] First, the present invention provides a foundation strengthening structure at the bottom of the installation positions of at least some production equipment in the production line area. This structure is composed of prestressed high-strength concrete pipe piles, a gravel cushion layer and a foundation support platform. Through this combination method, the weights of the production equipment and the precast box girder can be evenly distributed to the foundation, greatly enhancing the bearing capacity of the foundation; this enables the production line to operate stably in the face of sites with different geological conditions, effectively reducing the production risks caused by foundation condition limitations.

[0036] Second, the traditional precast box girder production plan has high requirements for foundation conditions. When the foundation conditions are not met, large-scale foundation treatment work often needs to be carried out, which not only consumes a large amount of funds but also prolongs the construction period. However, due to its strong foundation adaptability, the production line of the present invention reduces the dependence on foundation treatment to a certain extent, reduces the cost investment in the early project preparation stage, and at the same time avoids the construction period delay problem caused by foundation treatment, providing a strong guarantee for the smooth progress of the project.

[0037] Third, by scientifically and reasonably planning each functional area, the production line 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, greatly reducing the waiting time between processes and the time loss of material transfer, enabling the precast box girder to flow quickly in each production stage, thus achieving a substantial increase in production efficiency and fully meeting the high production capacity requirements of large-scale highway construction projects for precast box girders.

[0038] Fourth, in the traditional precast box girder production line, it is usually necessary to arrange a separate internal mold storage area and bottom mold turning area for storing the internal mold and adjusting the transportation direction of the bottom mold respectively. In the present invention, by setting an internal mold maintenance vehicle, the function of the internal mold maintenance vehicle to horizontally move and adjust the position of the internal mold can effectively avoid the bottom mold transport vehicle for adjusting the transport direction of the bottom mold. Therefore, there is no need to separately set up an independent internal mold storage area and bottom mold turning area, and the internal mold storage area and bottom mold turning area are combined into a mold maintenance area, thereby reducing the floor area of the production area, improving the utilization rate of site space, reducing the site construction and operation costs, making the precast box girder production site planning more compact and reasonable, enhancing the economy and flexibility of the overall production system, and optimizing the layout of the site. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The specification drawings forming a part of this application are used to provide a further understanding of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention. Among them:

[0040] Figure 1 is a top view of the precast box girder production line according to an embodiment of the present invention;

[0041] Figure 2 is a top view of the mold maintenance area and the concrete pouring area according to an embodiment of the present invention;

[0042] Figure 3 is a schematic diagram of an application state of a foundation strengthening structure according to an embodiment of the present invention;

[0043] Figure 4Another application state schematic diagram of the foundation strengthening structure according to an embodiment of the present invention;

[0044] Figure 5 Schematic diagram of the structure at a pouring station in a concrete pouring area according to an embodiment of the present invention;

[0045] Figure 6 Schematic diagram of the removal of the internal mold according to an embodiment of the present invention;

[0046] Figure 7 Elevation view of a perspective of the beam storage area according to an embodiment of the present invention;

[0047] Figure 8 Elevation view of another perspective of the beam storage area according to an embodiment of the present invention;

[0048] Figure 9 Schematic diagram of the working state of the steam curing area according to an embodiment of the present invention;

[0049] Figure 10 Elevation view of the concrete pouring area according to an embodiment of the present invention;

[0050] Figure 11 Schematic diagram of the overall structure of the internal mold maintenance vehicle according to an embodiment of the present invention;

[0051] Figure 12 For Figure 11 Enlarged structure schematic diagram of part A in

[0052] Figure 13 Schematic diagram of the mobile frame structure according to an embodiment of the present invention;

[0053] Figure 14 Schematic diagram of the cleaning of the top wall of the internal mold according to an embodiment of the present invention;

[0054] Figure 15 Schematic diagram of the cleaning of the side wall of the internal mold according to an embodiment of the present invention;

[0055] Figure 16 Schematic diagram of the cleaning of the top chamfer of the internal mold according to an embodiment of the present invention.

[0056] In the figure: 100, steel bar processing area; 110, intelligent overhead crane; 120, top plate processing equipment; 130, adjusting blanking equipment; 140, welding equipment; 150, bending equipment; 160, steel bar blanking area; 200, mold maintenance area; 210, internal mold maintenance vehicle; 211, support frame; 212, transverse moving wheel; 213, pulling unit; 214, pulling rope; 215, cleaning brush roller; 216, lifting and adjusting structure; 217, moving frame; 218, telescopic structure; 220, bottom mold transport vehicle; 230, internal mold; 240, bottom mold; 241, jacking device; 300, concrete pouring area; 310, distributing trolley; 320, side mold; 400, steam curing area; 410, steam curing shed; 420, spray pipeline; 430, steam pipeline; 440, concrete mixing plant; 450, transport track; 460, torpedo ladle; 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 discharging passage; 800, foundation strengthening structure; 810, prestressed high-strength concrete pipe pile; 820, gravel cushion layer; 830, foundation support platform; 840, connecting piece; 900, precast track; 910, production track; 920, slewing track; 921, transverse moving section; 922, transverse moving equipment. Detailed implementation manners

[0057] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Apparently, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art shall fall within the protection scope of the present invention.

[0058] In the description of the present invention, the orientation or positional relationships indicated by the terms "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", etc. are based on the orientation or positional relationships shown in the drawings, and are only for the convenience of describing the present invention rather than requiring the present invention to be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting 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 fixedly connected or detachably connected; they can be directly connected or indirectly connected through intermediate components. For those of ordinary skill in the art, the specific meanings of the above terms can be understood according to specific situations.

[0059] The present invention will be described in detail below with reference to the drawings and in conjunction with the embodiments. It should be noted that, without conflict, the embodiments and features in the embodiments of the present invention can be combined with each other.

[0060] The shapes and sizes of the components in the drawings do not reflect the actual scale of the product, and the purpose is only to schematically illustrate the content of the present invention.

[0061] The present invention provides a precast box girder production line. By reasonably arranging each functional area and closely connecting the production links, the waiting time for processes and the material transfer time are reduced, and the production efficiency is improved; at the same time, the dependence on foundation treatment is reduced, the upfront cost and the risk of construction period delay are lowered, and the internal mold storage area and the bottom mold rotation area are combined, reducing the floor area of the production area and improving the utilization rate of the site space. For the specific technical solution, please refer to the following embodiments:

[0062] Embodiment 1

[0063] As Figure 1-16 shown, specifically refer to Figure 1 , the precast box girder 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 precast track 900 is arranged 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 for transporting processing equipment in each of the above areas.

[0064] The steel bar processing area 100 is used to process the steel bar skeletons of precast box girders. In this area, professional steel bar processing equipment is arranged in an orderly manner. These mature steel bar processing equipment usually include an intelligent overhead crane 110, a top plate processing equipment 120, an adjustment and cutting equipment 130, a welding equipment 140, a bending equipment 150, etc. They work together to perform precise straightening, bending, cutting operations and assembly on the steel bars, and finally make the steel bars into steel bar skeletons that meet the design requirements, providing a solid structural foundation for the subsequent box girder pouring. The detailed processing method of the specific steel bar skeleton can refer to the Chinese invention patent application with the publication number CN118682045A, which will not be elaborated here. A steel bar cutting area 160 is arranged at one end of the steel bar processing area 100 away from the mold maintenance area 200 for receiving the raw materials transported into the production line. In this way, the steel bar transport vehicle transports the steel bars to the steel bar cutting area 160, and is hoisted to the positions of each processing equipment by the intelligent overhead crane 110, 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 lowering the construction cost of the production line.

[0065] As Figure 1 , Figure 2As shown in the figure, 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 overhead 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 transfer 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.

[0066] As Figure 11 shown, the bottom mold transport vehicle 220 includes a vehicle body that can run longitudinally along the prefabricated track 900, and the bottom mold 240 is arranged on the top of the vehicle body. The operation of the vehicle body can be intelligently controlled through existing programming. Specifically, after receiving the transfer instruction, the bottom mold transport vehicle 220 starts and accurately transports the bottom mold 240 to the designated position.

[0067] The internal mold maintenance vehicle 210 includes a support unit, a pulling unit 213, and a cleaning unit.

[0068] The support unit has a support frame body 211 and transverse moving wheels 212 for receiving, supporting, and laterally transporting the inner mold 230. Specifically, the support frame body 211 is a frame structure made of welded steel pipes and generally in a cuboid shape, with widened structures on both sides at the top for conveniently placing the inner mold 230 and allowing part of the cleaning unit of the cleaning unit to move along the top of the support frame body 211 for cleaning work. The transverse moving wheels 212 are arranged at the bottom of the support frame body 211 and the rolling direction is perpendicular to the length extension direction of the inner mold 230, so that the support unit can carry the inner mold 230 and move laterally in the width direction within the mold maintenance area 200.

[0069] The pulling unit 213 is arranged at one end of the support frame body 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 installed at one end of the support frame body 211 away from the concrete pouring area 300. The winch has a towing rope 214 for pulling the inner mold 230, and this towing rope 214 has sufficient tensile strength to withstand the pulling requirements of the inner mold 230.

[0070] The cleaning unit is used to clean the outer surface of the inner mold 230.

[0071] 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 parts 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 linearly back and forth along the top of the support unit to clean the inner mold 230.

[0072] As Figure 12As 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.

[0073] like Figure 13 , Figure 14 , Figure 15 , Figure 16 As 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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 internal mold 230 by lateral movement, compared with the traditional separate arrangement of the internal mold storage area and the bottom mold rotation area, the technical solution of the present invention only needs to set up a mold maintenance area 200, which can simultaneously realize the storage of the internal mold 230 and the adjustment of the transportation direction of the bottom mold 240, effectively reducing the floor area of the production area and improving the utilization rate of the site space.

[0078] As Figure 2 、 Figure 5 shown, the concrete pouring area 300 is used for pouring box girders. There are professional concrete pouring equipment in the concrete pouring area 300, and the pouring equipment includes a distributing trolley 310 and the side mold 320 of the box girder. In this area, the internal mold 230, the bottom mold 240 and the side mold 320 are assembled, and then the distributing trolley 310 distributes and pours concrete. During the pouring process, the operator controls the pouring speed and pouring volume of the concrete according to the design requirements of the precast box girder to ensure that the concrete is evenly filled into each part 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 discharges the air bubbles in the concrete through high-frequency vibration, improving the compactness and strength of the concrete.

[0079] 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 transportation track 450 for transporting torpedo cans 460 is arranged above the steam curing area 400. Specifically, the mixed concrete is transported to the distributing trolley 310 through the torpedo can 460, and then the distributing trolley 310 performs subsequent pouring work. For details, please refer to Figure 1 、 Figure 10 。

[0080] The poured box girder is then transferred to the steam curing area 400. As Figure 1 、 Figure 9 shown, the steam curing area 400 is used for steam curing of the box girder. A special steam curing shed 410, a steam generating device and a temperature and humidity control system are provided in the steam curing area 400. When the box girder enters the steam curing shed 410 in the steam curing area 400, the spray pipeline 420 and the steam pipeline 430 of the steam generating device start to work, delivering high-temperature steam to the curing area, so that the temperature and humidity in the curing area quickly rise to the set value. During the curing process, the temperature and humidity control system monitors the changes in temperature and humidity in the curing area in real time and automatically adjusts the steam supply volume and ventilation volume according to the monitoring data to ensure the stability of the curing environment. Through steam curing, the hydration reaction of the concrete can be accelerated, the early strength of the concrete can be improved, and the curing time can be shortened.

[0081] After the steam curing reaches the specified time, the box girder is transported to the natural curing area 500 for further natural curing. The natural curing area 500 is equipped with facilities such as sunshades and rain shelters, providing a suitable natural curing environment for the box girder. During the natural curing process, the concrete continues to undergo hydration reactions, and its strength gradually increases. The operators regularly detect the strength of the box girder to ensure that the strength of the box girder meets the requirements for tensioning strength.

[0082] The cured box girder is transported to the tensioning area 600. The tensioning area 600 is used for installing and tensioning 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 operators pass the prestressed steel bars through the reserved ducts of the box girder and fix both ends of the steel bars. Then, the tensioning equipment 610 applies tension to the prestressed steel bars, causing the steel bars to undergo elastic deformation, 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 the tensioning operation, the bearing capacity and crack resistance of the box girder can be improved.

[0083] The box girder that has completed the tensioning operation is finally transported to the beam storage area 700 for storage. As Figure 1 、 Figure 7 、 Figure 8 shown, the beam storage area 700 is used for storing the processed box girders. The beam storage area 700 is equipped with gantry cranes 720 and beam storage pedestals 710. Among them, the beam storage pedestals 710 are used to support the box girders, and the box girders are placed on the beam storage pedestals 710 in a certain order and spacing. The gantry cranes 720 are used to lift and transport the box girders. During the beam storage process, the box girders are regularly inspected and maintained to ensure the quality and safety of the box girders.

[0084] The precast track 900 in the above production line includes a production track 910 and a rotary track 920. The production track 910 crosses the processing stations in each functional area, while the rotary track 920 avoids the processing stations and is used for the rotation of equipment. Specifically, transverse movement sections 921 are arranged at both ends of the rotary track 920, and transverse movement equipment 922 (such as a transverse ferry vehicle) is provided on the transverse movement sections 921 to assist the processing equipment in turning and transporting directions.

[0085] In order to enhance the bearing capacity of the foundation within the above production line area, a foundation strengthening structure 800 is provided at the bottom of the installation positions of at least some production equipment.

[0086] In this embodiment, specifically, the foundation strengthening structure 800 is arranged at the positions of the running tracks 721 of the precast track 900, the tensioning equipment 610, and the gantry cranes 720.

[0087] As Figure 3 、 Figure 4As shown in the figure, the foundation strengthening structure 800 includes prestressed high-strength concrete pipe piles 810 (Prestressed High-strength Concrete Pile, abbreviated as PHC piles), a gravel cushion layer 820, and a foundation support platform 830.

[0088] The 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 tip, the weight of the upper equipment and the box girder is transmitted to the deep and stable soil layer, which can quickly improve the bearing capacity and stability of the soft foundation and reduce the treatment workload of the soft foundation. The gravel 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 the disturbance of the foundation soil. The foundation support platform 830 is arranged on the top of the gravel cushion layer 820 and is made of reinforced concrete structure, which has sufficient strength and stiffness to firmly support the production equipment and ensure the stability of the equipment during operation.

[0089] In addition, a connecting piece 840 is arranged on the top of the prestressed high-strength concrete pipe pile 810. The connecting piece 840 extends through the gravel cushion layer 820 and is integrally cast inside the foundation support platform 830. The connecting piece 840 includes a diffusion section and a core filling section which are integrally arranged. The core filling section is used for fixedly connecting with the top of the prestressed high-strength concrete pipe pile 810 and passing through the gravel cushion layer 820. The width of the diffusion section gradually decreases 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.

[0090] The specific working process of the present invention is as follows:

[0091] In the first step, the steel bar transport vehicle transports the steel bars to the steel bar cutting area 160, and then the intelligent overhead crane 110 in the steel bar processing area 100 hoists them to the positions of each processing equipment for processing. Finally, the steel bars are processed into the steel bar skeleton of the box girder.

[0092] In the second step, after the steel bar skeleton is processed, it is hoisted by the intelligent overhead crane 110 onto the bottom mold 240 of the mobile bottom mold transport vehicle 220. The mobile 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 transported to the concrete pouring area 300. In the concrete pouring area 300, the side mold 320 and the bottom mold 240 are closed.

[0093] In the third step, the concrete is prepared by the concrete mixing plant 440, transported by the torpedo ladle 460 to above the concrete pouring area 300, and then discharged to the distributing trolley 310. The distributing trolley 310 then carries out the concrete pouring operation, and the concrete vibrating operation is carried out synchronously during the pouring process until the concrete pouring process is completed.

[0094] In the fourth step, after the concrete pouring is completed, the concrete is left to stand still until the concrete in the box girder reaches final set.

[0095] In the fifth step, after the concrete reaches final set, the internal formwork 230 is controlled to retract inwards, and the lifting device 241 on the bottom formwork 240 rises and jacks up the internal formwork 230. Please refer to Figure 6 , and then the internal formwork 230 is pulled out of the box girder by the pulling unit 213 of the internal mold maintenance vehicle 210 to complete the demolding.

[0096] In the sixth step, after the box girder is demolded, the bottom formwork transport vehicle 220 transports the precast box girder along the production track 910 to the steam curing area 400, and the precast box girder is steam cured through the steam curing shed 410.

[0097] In the seventh step, after the steam curing is completed, the bottom formwork transport vehicle 220 transports the precast box girder along the production track 910 to the natural curing area 500 for outdoor spray curing until the tensile strength is reached.

[0098] In the eighth step, after the natural curing is completed, the bottom formwork transport vehicle 220 transports the precast box girder along the production track 910 to the tensioning area 600, and the prestressing tendons are threaded through the precast box girder and prestressed tensioning is carried out.

[0099] In the ninth step, after the tensioning is completed, the gantry crane 720 lifts the precast box girder from the bottom formwork transport vehicle 220, translates and transports it to the beam storage area 700 for beam storage, and grouting of the precast box girder is carried out in the beam storage area 700.

[0100] In the tenth step, after the precast box girder is lifted, the bottom formwork transport vehicle 220 returns to the mold maintenance area 200 through the slewing track 920, and with the assistance of the lateral moving device 922, returns to the production track 910 and then continues to pick up the precast box girder steel skeleton from the steel bar processing area 100 for the next production cycle.

[0101] In the eleventh step, after the grouting and curing of the precast box girder are completed, the precast box girder is lifted from the beam storage pedestal 710 by the gantry crane 720, translated to the beam exit channel 730, and transported to the site for installation by the beam transport gun car.

[0102] It can be understood that the above description is only exemplary, and the embodiments of the present application do not limit this.

[0103] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle 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; 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), the basic support platform (830) being arranged on top of the gravel cushion layer (820) and used for supporting the production equipment; 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); The connecting piece (840) comprises a diffuser section and a core-filling section which are integrally arranged, the core-filling section being used to be fixedly connected to the top of the prestressed high-strength concrete pipe pile (810) and passing through the gravel cushion layer (820), and the diffuser section gradually decreasing in width from top to bottom; The mold maintenance area (200) is provided with an internal mold maintenance vehicle (210) and a bottom mold transport vehicle (220), wherein 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); 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).

2. The prefabricated box girder production line according to claim 1, 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).

3. The prefabricated box girder production line according to claim 2, 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.

4. The prefabricated box girder production line according to claim 1, 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).

5. The prefabricated box girder production line according to claim 4, 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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