Storage and curing apparatus and method for precast segments

Abstract

The application provides a device and method for storing and maintaining prefabricated segments, which comprises a base including two parallel steel beams; support units arranged at intervals on the base, each set of support units including an arc-shaped channel steel and a rubber pad arranged on the arc-shaped channel steel for supporting the prefabricated segments; a spraying unit including spraying nozzles arranged between adjacent support units for spraying water to maintain the prefabricated segments; a monitoring unit including pressure sensors arranged below the rubber pads and temperature and humidity sensors arranged on the sides of the support units; and a control system in signal connection with the spraying unit, the monitoring unit and a foldable tarpaulin assembly. The application significantly improves the maintenance quality and construction efficiency of the prefabricated segments, reduces the labor cost and water resource consumption, and is suitable for the storage and maintenance of various prefabricated segments.

Description

Technical Field

[0001] This invention belongs to the field of storage and maintenance technology of precast concrete segments for wind power hybrid towers, specifically relating to a device and method for storing and maintaining precast segments. Background Technology

[0002] After the precast segments of a wind turbine hybrid tower are demolded, they are typically cured in the open air at the component factory. However, this traditional storage method faces numerous technical challenges: limited storage space in the factory leads to chaotic and disorderly storage; extensive curing methods result in untimely water spraying; and the mismatch between the production sequence of precast segments and their storage location affects management efficiency. These problems not only reduce the utilization rate of factory space but may also compromise the later strength of the components. With the increase in the number of precast segments, traditional water spraying curing methods consume a large amount of water resources and labor costs, and it is difficult to achieve precise timed and quantitative spraying. Especially in extreme weather conditions such as wind, rain, or low temperatures, the open-air storage environment severely affects the quality of segment repair and surface coating, thereby slowing down the construction progress of the entire wind turbine hybrid tower.

[0003] Most existing concrete curing equipment has only one function and cannot meet the large size characteristics and intelligent curing needs of precast tunnel segments for wind power hybrid towers. There is an urgent need to develop a device that can meet the traditional storage function while achieving all-weather, heat preservation and moisture retention, automatic spraying and automated management. Summary of the Invention

[0004] This invention provides a device and method for storing and maintaining precast tunnel segments, which solves the problems that existing maintenance equipment cannot meet the large size characteristics and intelligent maintenance needs of precast tunnel segments in wind power hybrid towers.

[0005] In a first aspect, the present invention provides a device for storing and maintaining precast tunnel segments, characterized in that it comprises: The base consists of two parallel steel beams; Support units are spaced apart on the base. Each support unit includes an arc-shaped channel steel and a rubber pad on it for supporting the precast segments. The spraying unit includes spray nozzles disposed between adjacent support units for spraying water to cure the precast segments. The monitoring unit includes a pressure sensor located under the rubber pad and a temperature and humidity sensor located on the side of the support unit; The control system is signal-connected to the spray unit, monitoring unit, and foldable tarpaulin assembly.

[0006] Compared with existing technologies, the advantages of this invention are as follows: The use of a support unit in conjunction with a monitoring unit achieves precise positioning and stable support for precast tunnel segments, significantly improving site space utilization; the spray unit combined with the monitoring unit can automatically adjust spray parameters according to environmental conditions, ensuring maintenance quality while significantly saving water resources; the foldable tarpaulin assembly provides all-weather protection, effectively coping with various severe weather conditions; the control system enables remote monitoring and management, allowing operators to monitor the segment status at any time and make necessary adjustments; it not only significantly improves the maintenance quality and construction efficiency of precast tunnel segments but also reduces labor costs and water consumption, demonstrating outstanding economic and social benefits, and is suitable for the storage and maintenance needs of various types of precast tunnel segments.

[0007] Furthermore, the inner wall of the steel beam is provided with continuous guide rails, and the support unit slides in conjunction with the guide rails via a slider.

[0008] Furthermore, the slider of the support unit is also equipped with a magnetic self-locking device, including: The magnetic box is fixedly installed at the bottom of the slider; Neodymium iron boron permanent magnets are embedded inside the magnetic box; A magnetic control switch is located on the side of the magnetic box; The magnetic control switch can switch the open / closed state of the magnetic self-locking device. When it is open, the neodymium iron boron permanent magnet generates magnetic attraction to fix the slider tightly to the guide rail. When it is closed, the magnetic attraction is released to achieve sliding adjustment.

[0009] Furthermore, it also includes: a foldable tarpaulin assembly, comprising a foldable frame and a tarpaulin, which are slidably connected to the base; the foldable frame is a U-shaped structure with the opening facing downwards, and the tarpaulin is fixedly covered on the outer surface of multiple foldable frames; the upper flange of the steel beam is provided with a slide rail, and the two ends of the foldable frame are slidably connected to the slide rail via rollers.

[0010] Furthermore, the control system includes: The control box is located in one corner of the base; The PLC controller, located inside the control box, is connected to the spray unit, monitoring unit, and foldable tarpaulin assembly via signals. A touch screen display is located on the surface of the control box; 5G communication module integrated into PLC controller; Warning lights are located on the outer surface of the control box.

[0011] Furthermore, the touch screen displays the precast segment number, production date, curing age, and corresponding rebound strength and ambient temperature and humidity data in real time.

[0012] Secondly, the present invention provides a method for storing and maintaining precast tunnel segments, using the storage and maintenance device for precast tunnel segments described in the first aspect, comprising the following steps: S1. Adjust the spacing between the support units, hoist the precast segments above the support units, and confirm their placement using pressure sensors; S2. Input the information of the precast tunnel segments into the control system and start the curing process, and record the curing data; S3. Control the opening and closing of the spray unit and the foldable tarpaulin assembly according to the data from the monitoring unit, and lift the precast segments after the curing treatment is completed.

[0013] Furthermore, the spraying unit adopts an intermittent mode, with the spraying duration and interval dynamically adjusted according to the maintenance stage.

[0014] Furthermore, maintenance data is transmitted in real time to mobile terminals via 5G networks for remote monitoring and emergency control. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of a storage and maintenance device according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the placement of precast segments in one embodiment of the present invention; Figure 3 This is a detailed schematic diagram of a foldable tarpaulin assembly according to an embodiment of the present invention; Figure 4 This is a front elevation view of the storage and maintenance device according to an embodiment of the present invention; Figure 5 This is a side elevation view of the storage and maintenance device according to an embodiment of the present invention; Figure 6 This is a top view of a storage and maintenance device according to an embodiment of the present invention.

[0016] Explanation of reference numerals in the attached figures: 1. Control box; 2. Base; 3. Arc-shaped channel steel; 4. Rubber pad; 5. Spray unit; 51. Spray nozzle; 6. Warning light; 7. Temperature and humidity sensor; 8. Foldable tarpaulin assembly; 81. Rollers; 82. Folding frame; 9. Guide rail; 10. Precast segments. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions in the embodiments of this invention will be clearly and completely described below in conjunction with the embodiments of this invention. Obviously, the described embodiments are only some embodiments of this invention, not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0018] Please see Figures 1-6 The present invention provides a device for storing and maintaining precast tunnel segments, comprising: Base 2 includes two parallel steel beams; Support units are spaced apart on the base 2. Each support unit includes an arc-shaped channel steel 3 and a rubber pad 4 on it, which is used to support the precast segments 10. The spraying unit 5 includes spray nozzles 51 disposed between adjacent support units for spraying water to cure the precast segments 10. The monitoring unit includes a pressure sensor located below the rubber pad 4 and a temperature and humidity sensor 7 located on the side of the support unit. The control system is signal-connected to the spray unit 5, the monitoring unit, and the foldable tarpaulin assembly 8.

[0019] The storage and maintenance device for precast tunnel segments provided by this invention employs a support unit in conjunction with a monitoring unit to achieve precise positioning and stable support of the precast tunnel segments, significantly improving site space utilization. The spray unit, combined with the monitoring unit, can automatically adjust spray parameters according to environmental conditions, ensuring maintenance quality while significantly saving water resources. The foldable tarpaulin assembly provides all-weather protection, effectively coping with various severe weather conditions. The control system enables remote monitoring and management, allowing operators to monitor the segment status at any time and make necessary adjustments. This device not only significantly improves the maintenance quality and construction efficiency of precast tunnel segments but also reduces labor costs and water consumption, demonstrating outstanding economic and social benefits and is suitable for the storage and maintenance needs of various types of precast tunnel segments.

[0020] The base 2 is made of high-strength materials such as channel steel or I-beams, providing a basic carrier for the installation of the support unit, spray unit 5, electrical control pipeline, and foldable tarpaulin assembly 8.

[0021] Furthermore, the support unit consists of an arc-shaped channel steel 3, a rubber pad 4, and a self-locking device, primarily used to support the precast tunnel segment 10. When the precast tunnel segment 10 is placed on the support unit, the pressure sensor is triggered under pressure, sending feedback to the control interface to indicate that the position is occupied; otherwise, it is in an unloaded state. Additionally, the arc-shaped channel steel 3 can also move in four directions (front, back, left, and right), allowing the support unit to be adjusted according to the size of the tunnel segment.

[0022] The inner wall of the steel beam is provided with continuous guide rails 9, and the support unit slides in conjunction with the guide rails 9 via a slider. The slider of the support unit is also provided with a magnetic self-locking device, including: a magnetic box, fixedly installed at the bottom of the slider; a neodymium iron boron permanent magnet embedded inside the magnetic box; and a magnetic control switch located on the side of the magnetic box. The magnetic control switch can switch the on / off state of the magnetic self-locking device. When on, the neodymium iron boron permanent magnet generates magnetic attraction, tightly fixing the slider to the guide rails 9; when off, the magnetic attraction is released, allowing for sliding adjustment.

[0023] The spray unit 5 is mainly used to spray water to cure the precast segments 10. It is controlled by temperature and humidity sensors, or it can be controlled by the control interface.

[0024] The temperature and humidity sensor 7 is mainly used for real-time dynamic monitoring of the environment around the precast segment 10, thereby controlling the opening and closing of the spray unit 5 to achieve the goal of unmanned operation around the clock.

[0025] The foldable tarpaulin assembly 8 consists of a folding frame 82 and a tarpaulin, which is slidably connected to the base 2. The folding frame 82 has a downward-facing U-shaped structure, and the tarpaulin is fixedly covered on the outer surface of multiple folding frames 82. The upper flange of the steel beam is equipped with a slide rail, and the two ends of the folding frame 82 are slidably connected to the slide rail via rollers 81. The foldable tarpaulin assembly 8 is normally folded up, but can be unfolded as needed to provide full coverage of the pipe segments within the entire device, thereby creating a suitable and stable working environment and reducing the impact of external factors on the quality of the components.

[0026] The control system includes: a control box 1 located at one corner of the base 2; a PLC controller located inside the control box 1, which is connected to the spray unit 5, the monitoring unit and the foldable tarpaulin assembly 8; a touch screen display on the surface of the control box 1; a 5G communication module integrated into the PLC controller; and a warning light 6 located on the outer surface of the control box 1.

[0027] The control system is mainly used to control the output display, input control, start and stop of the sprinkler system, and opening and closing of the foldable tarpaulin of the entire device. It can also be connected to a mobile APP through 5G technology to realize remote monitoring and management by managers.

[0028] The control interface enables two-way interaction between output and input through a touch screen display. While displaying values ​​such as available space, segment number, production date, temperature and humidity, users can also call the control system through the interface to realize different functions of the device.

[0029] The alarm device is a red warning light. When it is necessary to locate the position of a certain segment, an order can be placed with one click through a mobile APP. At this time, the red warning light will light up, which can achieve the purpose of rapid location.

[0030] The present invention also provides a method for storing and maintaining precast tunnel segments, which uses the above-mentioned storage and maintenance device for precast tunnel segments 10 and includes the following steps: S1. Adjust the spacing between the support units, hoist the precast segment 10 above the support unit, and confirm its positioning using a pressure sensor; S2. Input the information of the precast segment 10 into the control system and start the curing process, and record the curing data; S3. Control the opening and closing of the spray unit 5 and the foldable tarpaulin assembly 8 according to the data of the monitoring unit, and lift the precast segment 10 after the curing treatment is completed.

[0031] Furthermore, the spray unit 5 adopts an intermittent mode, with the spraying duration and interval dynamically adjusted according to the maintenance stage. Maintenance data is transmitted in real time to mobile terminals via a 5G network for remote monitoring and emergency control.

[0032] The specific implementation method of the device in this application is as follows: First, the steel base 2 is assembled and fixed in a predetermined position in the factory area. The support unit composed of the arc-shaped channel steel 3 and the rubber pad 4 is connected to the guide rail 9 on the inner side of the steel beam of the base 2 through a slider to form an adjustable segment support structure. According to the size specifications of the prefabricated segment 10, the support unit is slidably adjusted along the guide rail 9 to adjust its spacing to a suitable position and then locked and fixed.

[0033] The precast segment 10 is hoisted onto the support unit, ensuring that the bottom of the segment is fully in contact with the rubber pad 4. The positioning status of the segment is confirmed by a pressure sensor embedded under the rubber pad 4. Subsequently, basic information such as the number and production date of the precast segment 10 is entered into the touch screen of the control box 1, and the control system automatically begins recording the curing age.

[0034] During operation, temperature and humidity sensors 7, located on the side of the support unit, monitor environmental parameters in real time. When the humidity is detected to be lower than the set threshold, the control system automatically activates the spray unit 5, which sprays the precast segments 10 with adjustable-angle spray nozzles 51 between adjacent support units. When the temperature is lower than the set threshold, the control system unfolds the foldable tarpaulin assembly 8 along the slide rail on the upper flange of the steel beam, forming a heat-insulating curing space. The tarpaulin assembly consists of multiple sets of U-shaped frames connected in series by hinge shafts. After unfolding, it forms a continuous all-round coverage structure, thereby creating a suitable and stable working environment and reducing the impact of external factors on the quality of the components.

[0035] During the maintenance period, operators can remotely monitor the status of the tunnel segments through a control system integrated with a 5G communication module. When a precast tunnel segment 10 reaches the predetermined maintenance age, the system triggers a flashing warning light 6 and sends a notification via a mobile app, facilitating rapid location and hoisting operations.

[0036] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; if these modifications and variations fall within the scope of the claims of the present invention and their equivalents, they should all be considered to be within the protection scope of the present invention.

Claims

1. A device for storing and curing precast tunnel segments, characterized in that, include: The base includes two parallel steel beams; support units are spaced apart on the base, each support unit including an arc-shaped channel steel and a rubber pad on it for supporting precast segments; a spray unit includes spray nozzles arranged between adjacent support units for spraying water to cure the precast segments; a monitoring unit includes a pressure sensor located below the rubber pad and a temperature and humidity sensor located on the side of the support unit; and a control system is connected to the spray unit, monitoring unit, and foldable tarpaulin assembly. The inner wall of the steel beam is provided with continuous guide rails, and the support unit slides with the guide rails through a slider; The slider of the support unit is also equipped with a magnetic self-locking device, including: a magnetic box, which is fixedly installed at the bottom of the slider; a neodymium iron boron permanent magnet, which is embedded inside the magnetic box; and a magnetic control switch, which is located on the side of the magnetic box. The magnetic control switch can switch the open / closed state of the magnetic self-locking device. When it is open, the neodymium iron boron permanent magnet generates a magnetic attraction force to fix the slider tightly to the guide rail. When it is closed, the magnetic attraction is released to achieve sliding adjustment. It also includes: a foldable tarpaulin assembly, comprising a foldable frame and a tarpaulin, which are slidably connected to the base; the foldable frame is a U-shaped structure with the opening facing downwards, and the tarpaulin is fixedly covered on the outer surface of multiple foldable frames; the upper flange of the steel beam is provided with a slide rail, and the two ends of the foldable frame are slidably connected to the slide rail via rollers; The control system includes: a control box located at one corner of the base; a PLC controller located inside the control box, which is connected to the spray unit, monitoring unit and foldable tarpaulin assembly; a touch screen display on the surface of the control box; a 5G communication module integrated into the PLC controller; and a warning light located on the outer surface of the control box. The touch screen displays the precast segment number, production date, curing age, and corresponding rebound strength and ambient temperature and humidity data in real time.

2. A method for storing and curing precast tunnel segments, comprising using the storage and curing device for precast tunnel segments as described in claim 1, characterized in that, Includes the following steps: S1. Adjust the spacing between the support units, hoist the precast segments above the support units, and confirm their positioning using pressure sensors; S2. Input the information of the precast segments into the control system and begin curing treatment, and record the curing data; S3. Control the opening and closing of the spray unit and the foldable tarpaulin assembly according to the data from the monitoring unit, and hoist the precast segments away after the curing treatment is completed.

3. The method for storing and maintaining precast tunnel segments according to claim 2, characterized in that, The spray unit adopts an intermittent mode, and the spraying duration and interval are dynamically adjusted according to the maintenance stage.

4. The method for storing and maintaining precast tunnel segments according to claim 2, characterized in that, Maintenance data is transmitted in real time to mobile terminals via 5G network for remote monitoring and emergency control.

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