Steel-concrete composite beam bridge deck slab modular prefabrication production line and beat control process thereof

Abstract

The invention discloses a steel-concrete composite beam bridge deck slab modular prefabrication production line and a beat control process thereof. The production line comprises a central control system, a material distribution system, a mold table circulating system, a mold table processing system, a maintenance system and a demolding system. The beat control process comprises vibration data acquisition and state monitoring, image recognition of concrete vibration quality, construction of a vibration quality evaluation function, steam curing procedure beat control and production beat linkage control; the factory-like flow line production mode of prefabrication production of the steel-concrete composite beam bridge deck slab is constructed, working procedure collaboration is improved and efficient production is achieved through working die table circulation operation, the production line runs according to the rhythm and is adjusted in real time under the central control system, and high efficiency, intelligence and automation of prefabrication production of the steel-concrete composite beam bridge deck slab are achieved.

Description

Technical Field

[0001] The invention relates to the technical field of bridge structure construction, and in particular to a modular prefabrication production line for steel-concrete composite beam bridge decks and a beat control process thereof. Background Art

[0002] Steel-concrete composite beam bridge deck is a bridge deck structural member that combines steel and concrete to form an integral force-bearing bridge deck. It is usually laid on the steel beam to form an integral structure that bears force through shear connectors. The production of traditional steel-concrete composite beam bridge decks mainly relies on on-site casting or semi-prefabrication technology, and there are the following prominent problems: 1) Low production efficiency: On-site casting is restricted by factors such as weather and site, with a long construction period, a high proportion of manual operations, and poor quality stability; 2) Serious waste of resources: Traditional processes require a large number of templates, support systems and temporary sites, low material turnover efficiency, and a large amount of construction waste; 3) Insufficient degree of industrialization: Lack of modular design, scattered production equipment, production rhythm depends on manual experience adjustment, and the connection between various processes is not smooth, which is prone to shutdowns waiting for materials or equipment idling.

[0003] To solve the above problems, establishing an automated integrated production system that adapts to the characteristics of bridge engineering has become an inevitable trend in the development of the industry. However, the existing automated integrated production system still has the following deficiencies in the modular design and beat control of concrete precast components of steel-concrete composite beam bridge decks: 1) Poor module compatibility and integration: Existing production lines are mostly designed for single-specification bridge decks, and the production processes are scattered and independent, resulting in complex logistics routes and low production efficiency; 2) Outdated beat control technology: Traditional production lines use fixed beat modes or rely on manual experience to adjust the beat, and cannot be coordinated and adjusted in real time according to product status and quality; 3) High energy consumption: Curing kilns, vibrating equipment, etc. consume a lot of energy, lack intelligent regulation, and have low energy utilization.

[0004] In addition, compared with on-site casting or semi-prefabrication processes, the production quality of concrete precast components of steel-concrete composite beam bridge decks is relatively easy to control, but the instability of concrete distribution and the differences in technical parameters of the vibration process and the steaming process may lead to fluctuations in the quality of the finished concrete products. In order to compensate for the quality fluctuations, adjustments such as extending the vibration time will deviate from the normal production rhythm. How to adjust the production rhythm accordingly according to the quality fluctuations of concrete during the vibration and steaming processes is an urgent problem to be solved in the production of concrete precast components of steel-concrete composite beam bridge decks. Summary of the invention

[0005] In view of the deficiencies of the prior art, the present invention applies for a modular prefabrication production line for the steel-concrete composite girder bridge deck and its beat control process. Through modular design, automated equipment integration, and intelligent beat control, it realizes the efficient, high-precision, and large-scale production of bridge decks, and solves the problems of low efficiency, unstable quality, and high costs in traditional processes.

[0006] In the first aspect of this application, a modular prefabrication production line for the steel-concrete composite girder bridge deck is disclosed, which includes a central control system, a batching system, a formwork circulation system, a formwork treatment system, a curing system, and a demolding system;

[0007] The central control system is used to monitor and control the batching system, the formwork circulation system, the formwork treatment system, the curing system, and the demolding system; the central control system includes a production management subsystem, a resource planning subsystem, a mixing plant control subsystem, a panoramic monitoring subsystem, and an intelligent decision-making subsystem; the panoramic monitoring subsystem is used to obtain the panoramic monitoring images of the production line, and uses convolutional neural network model technology to identify the vibration quality image features of the panoramic monitoring images;

[0008] The batching system includes a suspension bracket, a special mixing plant for bridge decks, a concrete conveyor, a batching machine, and a vibrating table; the vibrating table is used to vibrate and compact the concrete;

[0009] The formwork circulation system includes a formwork, walking wheels, driving wheels, an induction anti-collision device, and a ferry vehicle, and realizes docking with each work station of the batching system, the formwork treatment system, and the curing system through the ferry vehicle, forming an annular conveyor line for the formwork to flow between each work station;

[0010] The formwork treatment system includes a sweeper, an oil sprayer, a numerical control line marker, a surface roughening machine, a polishing and repairing machine, and a vibrating leveling machine; the sweeper is used to clean the residual waste on the formwork after the concrete is demolded; the oil sprayer is used to spray a release agent on the surface of the formwork; the surface roughening machine uses roughening blades to scratch longitudinal textures with a certain depth and width on the surface of the initial-set concrete; the vibrating leveling machine makes the upper surface of the concrete flat and smooth through the bottom leveling surface;

[0011] The curing system includes a steam curing kiln, and by controlling the temperature and humidity in the steam curing kiln, the concrete undergoes four stages of static stop, heating, heat preservation, and cooling in the steam curing kiln;

[0012] The demolding system is used for the automatic demolding of the formwork.

[0013] Preferably, the intelligent decision-making subsystem includes a vibration rhythm adjustment unit, a steam curing prediction unit, and a rhythm linkage adjustment unit; the vibration rhythm adjustment unit is connected to the panoramic monitoring subsystem and the vibrating table, and uses neural network model technology. Based on the historical data of the vibration process, according to the concrete density, real-time vibration energy, surface bubble distribution density, bleeding unevenness, and surface unevenness, it outputs a vibration rhythm adjustment strategy, including the vibration duration, amplitude, and frequency of the vibrating table; the steam curing prediction unit is connected to the panoramic monitoring subsystem and the steam curing kiln, and uses long short-term memory network model technology. Based on the historical data of the steam curing process, according to the concrete density, vibration quality evaluation function, and steam curing process technical parameters during the concrete vibration process, it predicts the development curve of the concrete compressive strength over time; the rhythm linkage adjustment unit uses neural network model technology. Based on the historical data of the production line, according to the required duration of each process, it outputs the rhythm adjustment value of each process.

[0014] Preferably, the production process implemented by the steel-concrete composite bridge deck modular prefabrication production line includes the following process steps:

[0015] S101. Formwork cleaning: The formwork is sent to the cleaning station through the formwork circulation system, and the cleaning machine is controlled by the formwork processing system to remove the residual concrete waste, floating slurry, and dust on the formwork surface to ensure that the formwork surface is clean and free of debris;

[0016] S102. Oil spraying: The oil spraying machine is controlled by the formwork processing system to evenly spray the water-soluble release agent on the formwork surface and the inner wall of the side formwork;

[0017] S103. Steel bar placement into the formwork: The steel bar cage is steadily hoisted to the formwork by the hoisting frame controlled by the batching system;

[0018] S104. Formwork erection: Select the formwork according to the bridge deck size and connect it to the formwork with bolts. The four corners of the formwork are marked with yellow paint for positioning to ensure that the formwork is tightly spliced to prevent concrete leakage;

[0019] S105. Concrete batching: The concrete is transported to the production line by the torpedo tank; the batching machine is controlled by the batching system and automatically plans the walking track according to the component size; when the batching machine operates, it advances layer by layer from one end of the formwork to the other end, and the concrete at the corner parts is supplemented manually to avoid missing batching or accumulation;

[0020] S106. Vibration: The vibrating table is controlled by the batching system to clamp and fix the formwork, and then the concrete is vibrated until the surface bleeds and no obvious bubbles overflow;

[0021] S107. Levelling: The vibrating levelling machine is controlled by the formwork processing system to walk longitudinally along the formwork to level the concrete surface;

[0022] S108. Embedded placement: Embed the embedded parts at the designed positions in the concrete;

[0023] S109. Static roughening: Control the roughening machine through the table processing system to scratch longitudinal textures on the concrete surface;

[0024] S110. Steam curing: Send the table into the steam curing kiln through the table circulation system, and then cure the concrete with steam;

[0025] S111. Form removal: Remove the formwork and use special tools to clean the bonding points between the formwork and the concrete;

[0026] S112. Lifting: Control the hanging bracket through the batching system to hoist the concrete smoothly;

[0027] S113. Auxiliary treatment: Remove the residual floating slurry on the concrete surface, and use a steel brush to treat the floating slag that has not fallen off on the roughened surface; Spray information on the concrete, including the production date, slab number, and project location; Transfer the concrete to the spray curing area.

[0028] The second aspect of this application discloses a beat control process for a modular prefabrication production line of a steel-concrete composite girder bridge deck, including the following steps:

[0029] S201. Vibration data acquisition and status monitoring: Through the pressure sensor and acceleration sensor installed on the vibrating table, real-time collect the peak vibration force, vibration frequency, and amplitude data during the concrete vibration process, and the real-time vibration energy E a Satisfies the following expression:

[0030] E a = π·F max ·A·f·t

[0031] Among them, F max is the peak vibration force, N; A is the amplitude, m; f is the vibration frequency, Hz; t is the vibration time, s;

[0032] S202. Image recognition of concrete vibration quality: Through the linear array camera installed directly above the vibrating table, obtain the surface image during the concrete vibration, and then identify the image features through the intelligent decision subsystem; The image features include the apparent volume of the concrete, the distribution density of air bubbles on the concrete surface, the unevenness of bleeding, and the surface unevenness; Determine the concrete density D according to the apparent volume of the concrete, and satisfy the following expression:

[0033]

[0034] Among them, M is the concrete batching quality, V is the apparent volume of the concrete, and ρ max is the theoretical maximum density of the concrete;

[0035] S203. Construction of the vibration quality evaluation function: Construct the vibration quality evaluation function based on the concrete density, real-time vibration energy, concrete surface bubble distribution density, slurry unevenness, and surface unevenness; the vibration quality evaluation function Q v Satisfies the following expression:

[0036]

[0037] where E a is the real-time vibration energy, and E0 is the reference vibration energy; ρ b is the surface bubble distribution density, ρ b0 is the surface bubble distribution density threshold, ρ h is the slurry unevenness, ρ h0 is the slurry unevenness threshold, ρ p is the surface unevenness, ρ p0 is the surface unevenness threshold; α1, α2, α3, α4, and α5 are all weight coefficients, and their value ranges are all 0.1 - 0.3, and they satisfy α1 + α2 + α3 + α4 + α5 = 1; when Q v does not meet the requirements, input the concrete density, real-time vibration energy, surface bubble distribution density, slurry unevenness, and surface unevenness into the vibration rhythm adjustment unit, output the vibration rhythm adjustment strategy, and adjust the vibration duration, vibration table amplitude, and frequency according to the vibration rhythm adjustment strategy;

[0038] S204. Steam curing process rhythm control: According to the concrete density, vibration quality evaluation function, and steam curing process technical parameters during the concrete vibration process, predict the development curve of the concrete compressive strength through the intelligent decision-making subsystem, and calculate the current strength compliance rate and remaining curing duration in real time, and then dynamically divide the critical points of the static stop, heating, heat preservation, and cooling stages in the steam curing process; the steam curing process technical parameters include the temperature and humidity during steam curing; the strength compliance rate is the ratio of the concrete real-time compressive strength to the designed compressive strength;

[0039] S205. Production rhythm linkage control: Determine whether the vibration or steam curing process becomes the bottleneck process; the slowest process satisfies the following expression:

[0040] C = max(T1, T2,... T n )

[0041] where C is the slowest process, and T1, T2... T n are the required durations of each process; when the vibration process duration T i > C or the steam curing process duration T jWhen it is greater than C, the vibration process or the steam curing process becomes the new bottleneck process and triggers the linkage control of the production rhythm; through the intelligent decision-making subsystem, the rhythm adjustment values of each process are output according to the required duration of each process, and then the rhythms of each process are adjusted to make the durations of each process approach each other; the rhythm adjustment values of each process include the materials, labor, and equipment invested in each process.

[0042] Compared with the prior art, the beneficial effects of the present invention are as follows: aiming at the problems of low efficiency, unstable quality, and high cost in the traditional production process of the steel-concrete composite girder bridge deck, a modular prefabrication production line for the steel-concrete composite girder bridge deck and its rhythm control process are proposed. The production line includes a central control system, a batching system, a formwork circulation system, a formwork processing system, a curing system, and a demoulding system; a factory assembly line production mode for prefabricating the steel-concrete composite girder bridge deck is constructed, and the process coordination is improved and efficient production is realized through the transfer operation of the working formwork. Moreover, the production line operates according to the rhythm and is adjusted in real time under the central control system, realizing the high-efficiency, intelligent, and automated prefabrication production of the steel-concrete composite girder bridge deck; by decomposing the prefabrication production process of the steel-concrete composite girder bridge deck into 13 modular processes, the modularization of the production line and the seamless connection of the processes are realized; the rhythm control process includes vibration data acquisition and status monitoring, image recognition of the concrete vibration quality, construction of a vibration quality evaluation function, steam curing process rhythm control, and production rhythm linkage control; by monitoring the technical parameters of the concrete vibration process and constructing a vibration quality evaluation function, the evaluation and control of the concrete vibration quality are realized; according to the technical parameters of the vibration and steam curing processes, the development curve of the concrete compressive strength is predicted, and then the duration of the steam curing process is controlled; when the vibration or steam curing process becomes the bottleneck process, the rhythms of each process are adjusted through neural network technology to reduce the adverse impact of the bottleneck process on the production line rhythm. Description of the Drawings

[0043] Figure 1 It is a module diagram of the modular prefabrication production line for the steel-concrete composite girder bridge deck shown in the embodiment of the present invention;

[0044] Figure 2 It is a flowchart of the production process realized by the modular prefabrication production line for the steel-concrete composite girder bridge deck shown in the embodiment of the present invention;

[0045] Figure 3 It is a flowchart of the rhythm control process of the modular prefabrication production line for the steel-concrete composite girder bridge deck of the present invention;

[0046] Reference numerals: 1 - Central control system, 11 - Production management subsystem, 12 - Resource planning subsystem, 13 - Mixing plant control subsystem, 14 - Panoramic monitoring subsystem, 15 - Intelligent decision-making subsystem, 2 - Concreting system, 21 - Suspender, 22 - Special mixing plant for bridge deck, 23 - Concrete conveyor, 24 - Concreting machine, 25 - Vibrating table, 3 - Table form circulation system, 31 - Table form, 32 - Walking wheel, 33 - Driving wheel, 34 - Inductive anti-collision device, 35 - Transfer car, 4 - Table form processing system, 41 - Sweeper, 42 - Oil spraying machine, 43 - Numerical control scribing machine, 44 - Texturing machine, 45 - Grinding and finishing machine, 46 - Vibration leveling machine, 5 - Curing system, 51 - Steam curing kiln, 6 - Demoulding system. Detailed implementation manners

[0047] The following further describes the implementation manners of the present invention in conjunction with the drawings and reference numerals, so that those skilled in the art can implement it after studying this specification. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0048] The first aspect of this application discloses a modular prefabrication production line for steel-concrete composite beam bridge decks, including a central control system 1, a concreting system 2, a table form circulation system 3, a table form processing system 4, a curing system 5, and a demoulding system 6;

[0049] The central control system 1 is used to monitor and control the concreting system 2, the table form circulation system 3, the table form processing system 4, the curing system 5, and the demoulding system 6; the central control system 1 includes a production management subsystem 11, a resource planning subsystem 12, a mixing plant control subsystem 13, a panoramic monitoring subsystem 14, and an intelligent decision-making subsystem 15; the panoramic monitoring subsystem 14 is used to obtain panoramic monitoring images of the production line and identify the vibration quality image features of the panoramic monitoring images by using convolutional neural network model technology;

[0050] The concreting system 2 includes a suspender 21, a special mixing plant for bridge deck 22, a concrete conveyor 23, a concreting machine 24, and a vibrating table 25; the vibrating table 25 is used to vibrate and compact the concrete;

[0051] The table form circulation system 3 includes a table form 31, walking wheels 32, driving wheels 33, an inductive anti-collision device 34, and a transfer car 35, and forms a circular conveyor line for the table form 31 to flow between each working station; the transfer car 35 is used for ferrying the table form between each working station;

[0052] The formwork processing system 4 includes a sweeper 41, an oil sprayer 42, a numerical control scribing machine 43, a hairing machine 44, a finishing grinder 45 and a vibrating leveling machine 46; the sweeper 41 is used to clean the residual waste on the formwork after the component is demolded; the oil sprayer 42 is used to spray a release agent on the surface of the formwork; the hairing machine 44 uses hairing blades to scribe longitudinal textures with a certain depth and width on the surface of the initial-set concrete; the vibrating leveling machine 46 makes the upper surface of the concrete flat and smooth through the bottom leveling surface;

[0053] The curing system 5 includes a steam curing kiln 51, and by controlling the temperature and humidity in the steam curing kiln 51, the concrete undergoes four stages of static stop, heating, heat preservation and cooling in the steam curing kiln 51;

[0054] The demolding system 6 is used for the automatic demolding of the formwork.

[0055] Preferably, the intelligent decision-making subsystem 15 includes a vibration rhythm adjustment unit, a steam curing prediction unit and a rhythm linkage adjustment unit; the vibration rhythm adjustment unit is connected to the panoramic monitoring subsystem 14 and the vibrating table 25, and uses neural network model technology. Based on the historical data of the vibration process, according to the concrete density, real-time vibration energy, surface bubble distribution density, bleeding unevenness and surface unevenness, it outputs a vibration rhythm adjustment strategy, including vibration duration, amplitude and frequency of the vibrating table; the steam curing prediction unit is connected to the panoramic monitoring subsystem 14 and the steam curing kiln 51, and uses long short-term memory network model technology. Based on the historical data of the steam curing process, according to the concrete density, vibration quality evaluation function and steam curing process technical parameters during the concrete vibration process, it predicts the development curve of the concrete compressive strength over time; the rhythm linkage adjustment unit uses neural network model technology. Based on the historical data of the production line, according to the required duration of each process, it outputs the rhythm adjustment value of each process.

[0056] Preferably, the production process realized by the steel-concrete composite girder bridge deck modular prefabrication production line includes the following process steps:

[0057] S101. Formwork cleaning: The formwork is sent to the cleaning station through the formwork circulation system 3, and the sweeper is controlled by the formwork processing system 4 to remove the residual concrete waste, floating slurry and dust on the surface of the formwork, ensuring that the surface of the formwork is clean and free of debris;

[0058] S102. Oil spraying: The oil sprayer 42 is controlled by the formwork processing system 4 to evenly spray the water-soluble release agent on the surface of the formwork and the inner wall of the side formwork;

[0059] S103. Steel bar placement into the formwork: The hoist 21 is controlled by the batching system 2 to smoothly lift and transport the steel bar skeleton to the formwork;

[0060] S104. Formwork erection: Select the formwork according to the size of the bridge deck and connect it to the formwork table through bolts. Mark the four corners of the formwork with yellow paint for positioning to ensure tight splicing of the formwork and prevent concrete leakage.

[0061] S105. Concrete placing: The concrete is transported to the production line by torpedo cans; the placing machine 24 is controlled through the placing system 2 and the walking track is automatically planned according to the size of the component; when the placing machine 24 operates, it advances layer by layer from one end of the formwork table to the other end, and the artificial auxiliary feeding is carried out at the corner parts of the concrete to avoid missing placement or accumulation.

[0062] S106. Vibration: The vibrating table 25 is controlled through the placing system 2 to clamp and fix the formwork table, and then the concrete is vibrated until the surface is covered with mortar and no obvious bubbles overflow.

[0063] S107. Levelling: The vibrating levelling machine 47 is controlled through the formwork table treatment system 4 to walk longitudinally along the formwork table to level the concrete surface.

[0064] S108. Embedded part placement: The embedded parts are embedded at the designed positions in the concrete.

[0065] S109. Static curing and texturing: The texturing machine 44 is controlled through the formwork table treatment system 4 to draw longitudinal textures on the concrete surface.

[0066] S110. Steam curing: The formwork table is sent into the steam curing kiln through the formwork table circulation system 3, and then the concrete is cured with steam.

[0067] S111. Formwork removal: Remove the formwork and use special tools to clean the bonding points between the formwork and the concrete.

[0068] S112. Lifting: The lifting frame 21 is controlled through the placing system 2 to hoist the concrete smoothly.

[0069] S113. Auxiliary treatment: Remove the residual floating mortar on the concrete surface and use a steel brush to treat the floating slag that has not fallen off on the textured surface; spray information on the concrete, including the production date, slab number and project location; transfer the concrete to the spray curing area.

[0070] The second aspect of the present application discloses a beat control process for a modular prefabrication production line of a steel-concrete composite beam bridge deck, including the following steps:

[0071] S201. Vibration data acquisition and status monitoring: Through the pressure sensor and acceleration sensor installed on the vibrating table 25, the peak vibration force, vibration frequency and amplitude data during the concrete vibration process are collected in real time, and the real-time vibration energy E a satisfies the following expression:

[0072] E a =π·F max ·A·f·t (1)

[0073] Among them, F max is the peak vibration force, N; A is the amplitude, m; f is the vibration frequency, Hz; t is the vibration time, s;

[0074] In specific implementation, the peak vibration force F max is 1500 N, the amplitude A is 0.003 m, the vibration frequency f is 100 Hz, and the vibration time t is 180 s. Then the real-time vibration energy E a is calculated as shown in the following formula:

[0075] E a = π·F max ·A·f·t = π×1500×0.003×100×180 = 254469 J (2)

[0076] That is, the real-time vibration energy E under this typical working condition a is 254469 J;

[0077] S202. Image recognition of concrete vibration quality: By using a linear array camera installed directly above the vibration table 25, the surface image during concrete vibration is obtained, and then the image features are recognized by the intelligent decision-making subsystem 15; the image features include the apparent volume of concrete, the distribution density of surface bubbles in concrete, the unevenness of bleeding, and the surface unevenness; the concrete density D is determined according to the apparent volume of concrete, and the following expression is satisfied:

[0078]

[0079] Among them, M is the mass of concrete placement, V is the apparent volume of concrete, and ρ max is the theoretical maximum density of concrete;

[0080] In specific implementation, the mass of concrete placement M is 7500 kg, the apparent volume of concrete V is 3 m 3 , the theoretical maximum density of concrete ρ max is 2800 kg / m 3 , then the concrete density D is calculated as shown in the following formula:

[0081]

[0082] That is, the concrete density D under this typical working condition is 89.3%;

[0083] S203. Construction of vibration quality evaluation function: According to the concrete density, real-time vibration energy, distribution density of surface bubbles in concrete, unevenness of bleeding, and surface unevenness, a vibration quality evaluation function is constructed; the vibration quality evaluation function Q v satisfies the following expression:

[0084]

[0085] Among them, E a is the real-time vibration energy, E0 is the reference vibration energy; ρ b is the surface bubble distribution density, ρ b0 is the surface bubble distribution density threshold, ρ h is the slurry unevenness, ρ h0 is the flooding unevenness threshold, ρ p is the surface roughness, ρ p0 is the surface roughness threshold; α1, α2, α3, α4 and α5 are all weight coefficients, with a value range of 0.1 to 0.3, and satisfying α1+α2+α3+α4+α5=1; when Q v When the requirements are not met, the concrete density, real-time vibration energy, surface bubble distribution density, slurry unevenness and surface unevenness are input into the vibration beat adjustment unit, the vibration beat adjustment strategy is output, and the vibration duration, vibration table amplitude and frequency are adjusted according to the vibration beat adjustment strategy;

[0086] S204, steam curing process rhythm control: according to the concrete density during the concrete vibration process, the vibration quality evaluation function and the technical parameters of the steam curing process, the concrete compressive strength development curve is predicted through the intelligent decision-making subsystem 15, and the current strength compliance rate and the remaining curing time are calculated in real time, and then the critical points of the static stop, heating, insulation and cooling stages in the steam curing process are dynamically divided; the strength compliance rate is the ratio of the real-time compressive strength of the concrete to the designed compressive strength;

[0087] In the specific implementation, the strength compliance rate corresponding to the critical point of the static and heating stage is 15%, the strength compliance rate corresponding to the critical point of the heating and insulation stage is 40%, and the strength compliance rate corresponding to the critical point of the insulation and cooling stage is 85%;

[0088] S205, production rhythm linkage control: determine whether the vibration or steaming process becomes a bottleneck process; the slowest process satisfies the following expression:

[0089] C=max(T1,T2,…T n ) (6)

[0090] Among them, C is the slowest process, T1, T2…T n is the time required for each process; when the vibration process takes T i >C or steaming process duration T jWhen it is greater than C, the vibration process or the steam curing process becomes the new bottleneck process and triggers the production rhythm linkage control; through the intelligent decision-making subsystem 15, the rhythm adjustment values of each process are output according to the required duration of each process, and then the rhythm of each process is adjusted so that the durations of each process approach each other; the rhythm adjustment values of each process include the materials, labor, and equipment invested in each process.

[0091] In specific implementation, the project relying on this application needs to precast a total of 7,624 steel-concrete composite beam bridge decks. By establishing a modular prefabrication production line for steel-concrete composite beam bridge decks, the current daily production capacity is 13 pieces per day, and the efficiency is increased by 40% compared with the traditional process, and the qualified rate of structural dimensions is 100%. It can be seen that this production line has accelerated the construction progress, reduced the construction cost, and ensured the construction quality.

[0092] Thus, it can be seen that building a factory-style assembly line production mode for prefabricating steel-concrete composite beam bridge decks can improve process coordination and achieve efficient production through the transfer operation of the working formwork. And the production line operates according to the rhythm and is adjusted in real time under the central control system to achieve the high-efficiency, intelligent, and automated prefabrication production of steel-concrete composite beam bridge decks; by decomposing the prefabrication production process of steel-concrete composite beam bridge decks into 13 modular processes, the modularization of the production line and the seamless connection of processes are realized; by monitoring the technical parameters of the concrete vibration process and constructing a vibration quality evaluation function, the evaluation and control of the concrete vibration quality are realized; according to the technical parameters of the vibration and steam curing processes, the development curve of the concrete compressive strength is predicted, and then the duration of the steam curing process is controlled; when the vibration or steam curing process becomes the bottleneck process, the rhythm of each process is adjusted through neural network technology to reduce the adverse impact of the bottleneck process on the production line rhythm.

[0093] The above are one or more embodiments of the present invention, and the description thereof is relatively specific and detailed, but it should not be construed as a limitation to the scope of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several deformations and improvements can still be made, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the appended claims.

Claims

1. Modular prefabrication production line for steel-concrete composite girder bridge deck, characterized in that, It includes a central control system, a batching system, a mold table circulation system, a mold table processing system, a curing system and a demolding system; the central control system is used to monitor and control the batching system, the mold table circulation system, the mold table processing system, the curing system and the demolding system; the central control system includes a production management subsystem, a resource planning subsystem, a mixing plant control subsystem, a panoramic monitoring subsystem and an intelligent decision-making subsystem; the panoramic monitoring subsystem is used to obtain panoramic monitoring images of the production line and use convolutional neural network model technology to identify the vibration quality image features of the panoramic monitoring images; the intelligent decision-making subsystem includes a vibration rhythm adjustment unit, a steam curing prediction unit and a rhythm linkage adjustment unit; the batching system includes a hanging bracket, a special mixing plant for bridge deck, a concrete conveyor, a batching machine and a vibrating table; the vibrating table is used to vibrate and compact the concrete; the vibrating screeding machine makes the upper surface of the concrete flat and smooth through the bottom screeding surface; the mold table circulation system includes a mold table, walking wheels, driving wheels, an induction anti-collision device and a ferry vehicle, and realizes docking with each working station of the batching system, the mold table processing system and the curing system through the ferry vehicle, forming a circular conveyor line for the mold table to flow between each working station; the mold table processing system includes a sweeper, an oil spraying machine, a numerical control scribing machine, a surface roughening machine, a repair and polishing machine and a vibrating screeding machine; the sweeper is used to clean the residual waste on the mold table after the concrete is demolded; the oil spraying machine is used to spray a mold release agent on the surface of the mold table; the surface roughening machine uses roughening blades to scratch longitudinal textures with a certain depth and width on the surface of the initial-set concrete; the curing system includes a steam curing kiln, and by controlling the temperature and humidity in the steam curing kiln, the concrete undergoes four stages of static stop, heating, heat preservation and cooling in the steam curing kiln; the demolding system is used for the automatic demolding of the mold table.

2. The modular prefabrication production line for the steel-concrete composite girder bridge deck according to claim 1, characterized in that, The vibration rhythm adjustment unit is connected to the panoramic monitoring subsystem and the vibrating table, and uses neural network model technology. Based on the historical data of the vibration process, according to the concrete density, real-time vibration energy, surface bubble distribution density, bleeding unevenness and surface unevenness, it outputs a vibration rhythm adjustment strategy, including vibration duration, vibration table amplitude and frequency; the steam curing prediction unit is connected to the panoramic monitoring subsystem and the steam curing kiln, and uses long short-term memory network model technology. Based on the historical data of the steam curing process, according to the concrete density, vibration quality evaluation function and steam curing process technical parameters during the concrete vibration process, it predicts the development curve of the concrete compressive strength over time; the rhythm linkage adjustment unit uses neural network model technology. Based on the historical data of the production line, according to the required duration of each process, it outputs the rhythm adjustment value of each process.

3. The modular prefabrication production line for the steel-concrete composite girder bridge deck according to any one of claims 1-2, characterized in that, The production process realized by the modular prefabrication production line for the steel-concrete composite beam bridge deck includes the following process steps: S101. Mold table cleaning: The mold table is sent to the cleaning station through the mold table circulation system, and the sweeper is controlled by the mold table processing system to remove the residual concrete waste, floating slurry and dust on the surface of the mold table to ensure that the surface of the mold table is clean and free of debris; S102, Injection: Control the injector through the table processing system to evenly spray the water-soluble release agent on the surface of the table and the inner wall of the side formwork; S103, Steel bar placement into the formwork: Control the hanging bracket through the batching system to steadily hoist the steel bar framework to the table; S104, Formwork erection: Select the formwork according to the size of the bridge deck slab and connect it to the table through bolts. Mark the four corners of the formwork with yellow paint for positioning to ensure tight formwork splicing and prevent concrete leakage; S105, Concrete batching: The concrete is transported to the production line by the torpedo ladle; Control the batching machine through the batching system and automatically plan the walking track according to the component size; When the batching machine is operating, it advances layer by layer from one end of the table to the other end. The corner parts of the concrete are supplemented manually to avoid missing batching or accumulation; S106, Vibration: Control the vibrating table through the batching system to clamp and fix the table, and then vibrate the concrete until the surface is covered with slurry and no obvious air bubbles overflow; S107, Levelling: Control the vibrating leveller through the table processing system to walk longitudinally along the table to level the concrete surface; S108, Embedded part placement: Embed the embedded parts at the designed positions in the concrete; S109, Static curing and surface roughening: Control the surface roughening machine through the table processing system to scratch longitudinal textures on the concrete surface; S110, Steam curing: Send the table into the steam curing kiln through the table circulation system, and then cure the concrete with steam; S111, Formwork removal: Remove the formwork and use special tools to clean the bonding points between the formwork and the concrete; S112, Hoisting: Control the hanging bracket through the batching system to steadily hoist the concrete; S113, Auxiliary treatment: Remove the residual floating slurry on the concrete surface and use a steel brush to treat the floating slag that has not fallen off on the roughened surface; Print information on the concrete, including the production date, slab number, and project location; Transfer the concrete to the spray curing area.

4. The beat control process of the modular prefabrication production line for the steel-concrete composite girder bridge deck is characterized in that, For the modular prefabrication production line of the steel-concrete composite beam bridge deck slab as described in any one of claims 1-3, it includes the following steps: S201. Vibration data acquisition and status monitoring: The peak vibration force, vibration frequency, and amplitude data during the concrete vibration process are collected in real time through the pressure sensor and acceleration sensor installed on the vibrating table, and the real-time vibration energy E a Satisfies the following expression: E a = π·F max ·A·f·t Among them, F max is the peak value of the vibration force, N; A is the amplitude, m; f is the vibration frequency, Hz; t is the vibration time, s; S202, Image recognition of concrete vibration quality: Obtain the surface images during concrete vibration through the line array camera installed directly above the vibrating table, and then identify the image features through the intelligent decision-making subsystem; The image features include the apparent volume of the concrete, the distribution density of air bubbles on the concrete surface, the unevenness of slurry covering, and the surface unevenness; Determine the concrete compactness D according to the apparent volume of the concrete, which satisfies the following expression: Where M is the mass of concrete placement, V is the apparent volume of concrete, and ρ max is the theoretical maximum density of concrete; S203. Construction of vibration quality evaluation function: Construct a vibration quality evaluation function based on concrete density, real-time vibration energy, concrete surface bubble distribution density, slurry unevenness, and surface unevenness; the vibration quality evaluation function Q v satisfies the following expression: Among them, E a is the real-time vibration energy, and E0 is the reference vibration energy; ρ b is the surface bubble distribution density, ρ b0 is the surface bubble distribution density threshold, ρ h is the mortar bleeding non-uniformity, ρ h0 is the mortar bleeding non-uniformity threshold, ρ p is the surface unevenness, ρ p0 is the surface unevenness threshold; α1, α2, α3, α4, and α5 are all weighting coefficients, and their value ranges are all 0.1 to 0.3, and they satisfy α1 + α2 + α3 + α4 + α5 = 1; when Q v does not meet the requirements, the rhythm of the vibration process is adjusted through the mixing plant control subsystem, and the vibration time is extended until Q v meets the requirements; S204, Control of the steam curing process rhythm: According to the concrete compactness, vibration quality evaluation function, and steam curing process technical parameters during the concrete vibration process, predict the development curve of the concrete compressive strength through the intelligent decision-making subsystem, and calculate the current strength compliance rate and the remaining curing duration in real time, and then dynamically divide the critical points of the static stop, heating, heat preservation, and cooling stages in the steam curing process; The strength compliance rate is the ratio of the real-time compressive strength of the concrete to the designed compressive strength; S205, Linked control of the production rhythm: Judge whether the vibration or steam curing process becomes the bottleneck process; The slowest process satisfies the following expression: C = max(T1, T2, … T n ) Among them, C is the slowest process, and T1, T2... T n are the required durations of each process; when the vibration process duration T i > C or the steam curing process duration T j > C, the vibration process or the steam curing process becomes the new bottleneck process and triggers the production beat linkage control; through the intelligent decision-making subsystem, the beat adjustment values of each process are output according to the required durations of each process, and then the beats of each process are adjusted to make the durations of each process approach each other; the beat adjustment values of each process include the materials, labor, and equipment invested in each process.

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