A production device for precast bridge slabs and a method of using the same
By combining low-position and high-position vibrators with ultrasonic sensors and drive frames, the problems of collision and obstruction between the vibrator and the reinforcing steel are solved, achieving efficient, continuous and energy-saving vibration of precast bridge slabs, and improving the density and uniformity of concrete.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- 江苏润海智造工程有限公司
- Filing Date
- 2025-08-15
- Publication Date
- 2026-06-09
AI Technical Summary
In existing precast bridge slab production equipment, the vibrator is prone to colliding with the reinforcing bars, causing local plastic deformation of the reinforcing bars. Furthermore, when encountering obstruction from the reinforcing bars, the machine needs to be stopped for adjustment, resulting in interruption of concrete vibration and affecting production quality.
By using low-position and high-position vibrators in combination, and combining ultrasonic sensors to predict the position of the reinforcing bars, the vibrator can be interchanged and oscillated slightly to avoid hard collisions. The drive frame moves the pusher to ensure continuous operation.
It achieves full-depth vibration coverage of concrete, avoids steel bar deformation and missed vibration, improves production quality and energy saving effect, and reduces manual intervention and energy consumption.
Smart Images
Figure CN120755974B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of precast bridge slab production technology, specifically to a precast bridge slab production apparatus and its usage method. Background Technology
[0002] In the industrial production of precast bridge slabs (such as simply supported beams, hollow slabs, and box girders), the vibration of concrete after it enters the mold using an immersion vibrator is a crucial step in ensuring the compactness, strength, and durability of the concrete structure. The compaction of concrete after pouring is a key process for guaranteeing the mechanical properties of the component. The immersion vibrator uses high-frequency vibration to liquefy the concrete, thereby expelling air bubbles, filling gaps between reinforcing bars, and preventing defects such as honeycomb and pitting. However, as a load-bearing structure, precast bridge slabs typically have a reinforcing steel skeleton inside. This skeleton is a three-dimensional framework formed by binding or welding reinforcing bars according to design requirements. It is the "skeleton" and core load-bearing system of the concrete structure. By working in conjunction with the concrete, the reinforcing steel skeleton can bear the load in the tension zone of the structure, preventing the concrete from cracking or failing due to tension.
[0003] The current production equipment and usage methods for precast bridge slabs often result in frequent contact between the vibrator and the reinforcing steel during the movement or insertion process. Although the reinforcing steel skeleton is fixed by binding or spot welding, the high-frequency vibration impact and direct collision of the vibrator can cause local plastic deformation of the reinforcing steel, disrupting the original design force path. Furthermore, when the vibrator is blocked by the reinforcing steel, it is necessary to stop the machine, adjust the insertion angle, pull it out and reinsert it, or change the vibration point. This process can cause local vibration interruption in the concrete, easily leading to missed vibration, air bubble accumulation, or aggregate voids, reducing the density of the concrete and lowering the production quality of the precast bridge slabs.
[0004] To address the above issues, a production device for precast bridge slabs and its usage method are proposed. Summary of the Invention
[0005] The purpose of this invention is to provide a production device for precast bridge slabs and its usage method. By using this invention, the problems mentioned above are solved, such as the need to stop the machine to adjust the insertion angle, pull out and re-insert, or replace the vibration point when the vibrator easily collides with the reinforcing bars, causing local plastic deformation of the reinforcing bars and obstruction by the reinforcing bars.
[0006] To achieve the above objectives, the present invention provides the following technical solution:
[0007] A precast bridge slab production apparatus includes a drive frame, inside which a mold is fixedly installed. A swinging component is fixedly installed on one side of the drive frame. A pushing component is slidably connected to the side of the drive frame near the swinging component, and one end of the pushing component is slidably connected to the swinging component. Several frames are provided at the bottom of the pushing component. A lifting component is fixedly installed on one side of the pushing component. A first movable seat is slidably connected to one side of the frame, and the first movable seat is rotatably connected to the lifting component. A first vibrator is installed at one end of the first movable seat. A second movable seat is slidably connected to the other side of the frame. The second movable seat is installed at a higher position than the first movable seat, and the first movable seat and the second movable seat are drively connected. A second vibrator is installed at one end of the second movable seat. Two opposing ultrasonic sensors are installed at an angle on one side of the frame. The ultrasonic sensors are electrically connected to the pushing component and the lifting component through a controller.
[0008] Furthermore, the drive frame includes a base and a first bracket fixed to one side of the base. A motor is fixedly installed at one end of the first bracket, and a screw is rotatably connected inside the first bracket. The screw is fixedly connected to the output end of the motor. A second bracket is fixedly installed on one side of the base, and a slide rod is fixedly installed inside the second bracket. A movable plate is threadedly connected to the surface of the screw, and the movable plate is slidably connected to the first bracket, the second bracket, and the slide rod.
[0009] Furthermore, the swinging component includes a fixed frame and a serpentine track fixed to one side of the fixed frame, with limit grooves provided on both sides of the serpentine track.
[0010] Furthermore, the pushing component includes a base plate and a housing fixed to one side of the base plate. An electric push rod is fixedly installed on one side of the housing. A mounting shell is fixedly installed on the surface of the electric push rod and is fixedly connected to the housing. A first toothed plate is slidably connected inside the housing. A mounting block is fixedly installed on one side of the first toothed plate and the output end of the electric push rod is fixedly connected to the mounting block. A T-shaped block is fixedly installed on the surface of the housing and is slidably connected to the moving plate. A roller is rotatably connected to one side of the T-shaped block and the roller is in contact with the inside of the moving plate.
[0011] Furthermore, a concave plate is fixedly installed at one end of the base plate, the concave plate is in contact with the serpentine track, rollers are rotatably connected to both sides of the concave plate, and the rollers are in contact with the limiting groove. A rectangular plate is fixedly installed on one side of the base plate, and two strip plates are installed on one side of the base plate near the rectangular plate.
[0012] Furthermore, a shaft is fixedly installed at one end of the frame, the shaft is rotatably connected to the base plate, a first gear is fixedly installed at one end of the shaft, and a first gear plate is meshed with the first gear. Slide grooves are opened inside both sides of the frame, and a support rod is rotatably connected inside the frame. A second gear is fixedly installed on the surface of the support rod.
[0013] Furthermore, the lifting component includes a cylinder and an annular frame fixed to one end of the cylinder. The output end of the cylinder is connected through to one side of the rectangular plate. Two contact rods are fixedly installed on one side of the annular frame, and both contact rods are slidably connected to two strip plates. An arc-shaped groove is opened inside the annular frame.
[0014] Furthermore, the first movable seat includes an L-shaped plate and a second toothed plate fixed to one side of the L-shaped plate. The L-shaped plate is slidably connected to the frame, and the second toothed plate is meshed with a second gear. First limiting blocks are fixedly installed on both sides of the L-shaped plate, and both first limiting blocks are slidably connected to the slide groove. A first damper is fixedly installed at one end of the L-shaped plate, and the first vibrator is fixedly connected to the first damper. A T-shaped rod is fixedly installed at the other end of the L-shaped plate, and the T-shaped rod is slidably connected to the arc groove.
[0015] Furthermore, the second movable seat includes a vertical plate and a third toothed plate fixed to one side of the vertical plate. The vertical plate is slidably connected to the frame, and the third toothed plate is meshed with a second gear. Second limiting blocks are fixedly installed on both sides of the vertical plate, and both second limiting blocks are slidably connected to the slide groove. A second damper is fixedly installed at one end of the vertical plate, and the second vibrator is fixedly connected to the second damper.
[0016] Another technical solution proposed by the present invention: a method for using a precast bridge slab production device, comprising the following steps;
[0017] S1: In the initial state, the low-position first vibrator and the high-position second vibrator can vibrate the concrete, and the drive frame can drive the pusher to move slowly. The low-position first vibrator vibrates the deep layer of the concrete, while the high-position second vibrator moves ahead and acts on the shallow layer. The two work together to form full-depth vibration coverage of the deep and shallow layers.
[0018] S2: When the first vibrator at the lower position is about to approach the steel bar, the ultrasonic sensor will detect the presence of steel bar in the direction of movement. By predicting the movement through the ultrasonic sensor and alternating between the first and second vibrators, the roles of the first and second vibrators can be interchanged. The primary and secondary vibration areas can be flexibly switched according to the distribution of steel bars, and the deformation of steel bars or damage to the first vibrator caused by hard collisions can be avoided.
[0019] S3: The oscillating component causes the pusher to oscillate slowly during its movement. The slow movement ensures that the first and second vibrators have sufficient time to act in each area, while the small oscillation allows the vibration energy to gradually diffuse to the periphery. The vibration is transmitted gradually from the center of the first and second vibrators to the edge, avoiding uneven vibration caused by sweeping over the area due to rapid movement, and thus greatly improving the vibration effect of the concrete.
[0020] S4: By using ultrasonic sensors to predict and alternating between the first and second vibrators, a continuous operation mode is achieved where the machine does not stop when encountering steel bars, only switching the working parts. When the first vibrator moves upward to avoid them, the second vibrator has already started vibrating synchronously, avoiding the instantaneous high energy consumption caused by frequent start-stop of a single device, thus achieving energy saving.
[0021] Compared with the prior art, the beneficial effects of the present invention are as follows:
[0022] 1. In the initial state, the first vibrator at the low position penetrates deep into the concrete to vibrate, while the second vibrator at the high position works on the surface and shallow areas, forming a layered vibration coverage of deep and shallow layers. This compensates for the insufficient coverage of the shallow layer by the first vibrator at the low position, and improves the overall density and uniformity of the concrete.
[0023] 2. When the ultrasonic sensor detects the reinforcing steel, the first and second vibrators switch positions and rotate continuously, avoiding direct contact between the first and second vibrators with the reinforcing steel, which could cause damage or jamming. This ensures that the switching can be repeated when the reinforcing steel is encountered again, solving the problem of forced shutdown due to reinforcing steel obstruction compared to traditional devices, and ensuring the continuity of the concrete vibration process.
[0024] 3. By using a swinging component, the pushing component is made to swing slightly during its movement. The slight swing expands from a circular area to a fan-shaped area, thereby expanding the coverage area and improving the efficiency of bubble discharge through path optimization.
[0025] 4. The entire process is automated through the linkage of ultrasonic sensors and mechanical structures, reducing manual intervention. Compared with the traditional manual operation mode that requires frequent machine stops and position adjustments, it can continuously complete the vibration operation and shorten the operation time of a single area.
[0026] 5. The first and second vibrators work alternately, realizing a continuous operation mode that does not stop when encountering steel bars, but only switches working parts. When the first vibrator moves upward to avoid them, the second vibrator has already started vibrating synchronously, avoiding the instantaneous high energy consumption of frequent start and stop of a single device, and achieving the effect of energy saving. Attached Figure Description
[0027] Figure 1 This is a schematic diagram of the overall structure of the present invention;
[0028] Figure 2 This is a schematic diagram of the drive frame structure of the present invention;
[0029] Figure 3 This is a schematic diagram of the first movable seat structure of the present invention;
[0030] Figure 4 This is a schematic diagram of the swing component structure of the present invention;
[0031] Figure 5 For the present invention Figure 4 Schematic diagram of the structure at point A in the middle;
[0032] Figure 6 This is a schematic diagram of the second movable seat structure of the present invention;
[0033] Figure 7 This is a schematic diagram of the framework structure of the present invention;
[0034] Figure 8 For the present invention Figure 7 Schematic diagram of the structure at point B.
[0035] In the diagram: 1. Drive frame; 11. Base; 12. First bracket; 13. Motor; 14. Screw; 15. Second bracket; 16. Slide rod; 17. Moving plate; 2. Mold; 3. Swinging component; 31. Fixed frame; 32. Serpentine track; 33. Limiting groove; 4. Pushing component; 41. Base plate; 411. Concave plate; 412. Roller; 413. Rectangular plate; 414. Strip plate; 42. Housing; 43. Electric push rod; 44. Mounting housing; 45. First toothed plate; 46. Mounting block; 47. T-block; 48. Roller; 5. Frame Frame; 51. Shaft; 52. First gear; 53. Slide groove; 54. Support rod; 55. Second gear; 6. Lifting component; 61. Cylinder; 62. Ring frame; 63. Contact rod; 64. Arc groove; 7. First moving seat; 71. L-shaped plate; 72. Second toothed plate; 73. First limiting block; 74. First damper; 75. T-shaped rod; 8. First vibrator; 9. Second moving seat; 91. Vertical plate; 92. Third toothed plate; 93. Second limiting block; 94. Second damper; 10. Second vibrator; 20. Ultrasonic sensor. Detailed Implementation
[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0037] To address the technical issue of the first vibrator 8 easily colliding with the reinforcing bars, causing localized plastic deformation and obstruction, requiring the machine to be stopped to adjust the insertion angle, pulled out and re-inserted, or the vibrating point to be replaced, such as... Figures 1-8 As shown, the following preferred technical solutions are provided:
[0038] like Figure 1As shown, a precast bridge slab production device includes a drive frame 1, which provides driving force to drive the subsequent structure to move back and forth. A mold 2 is fixedly installed inside the drive frame 1, and the mold 2 contains a steel reinforcement skeleton. By introducing concrete into the mold 2, the steel reinforcement skeleton forms a "circumferential constraint" on the core area of the concrete, which can prevent the concrete from expanding laterally under pressure, thereby improving its compressive strength and ductility. A swinging component 3 is fixedly installed on one side of the drive frame 1, and a pushing component 4 is slidably connected to the side of the drive frame 1 near the swinging component 3. One end of the pushing component 4 is slidably connected to the swinging component 3. When the drive frame 1 causes the pushing component 4 to move back and forth, the swinging component 3 causes the pushing component 4 to swing slightly during the movement. This slight swing is an efficient and safe vibration optimization method. By optimizing the path, the coverage area is expanded, the air bubble removal efficiency is improved, and the negative impact on the steel reinforcement and concrete structure is reduced.
[0039] The bottom of the pusher 4 is provided with several frames 5. The pusher 4 can push several frames 5 to rotate simultaneously. A lifting component 6 is fixedly installed on one side of the pusher 4. A first moving seat 7 is slidably connected to one side of the frame 5 and is rotatably connected to the lifting component 6. A first vibrator 8 is installed at one end of the first moving seat 7. The first vibrator 8 can vibrate the concrete. The high-frequency vibration will cause the concrete particles to have inertial displacement. After the air bubbles are squeezed by the vibration, they rise along the gaps between the aggregates and eventually escape to the surface, so that the concrete surface is smooth and flat, reducing the cost of later repairs, promoting the compaction of concrete, improving structural strength, ensuring the homogeneity of concrete, preventing segregation, and enhancing the bond between concrete and steel bars. The first vibrator 8 is powered by a wireless battery. The vibration structure is inside the vibrator rod and no external power cable is required.
[0040] A second movable seat 9 is slidably connected to the other side of the frame 5. The second movable seat 9 is installed at a higher position than the first movable seat 7, and the first movable seat 7 is connected to the second movable seat 9 by transmission. A second vibrator 10 is installed at one end of the second movable seat 9. The second vibrator 10 has the same structure as the first vibrator 8. The lower-position first vibrator 8 vibrates the bottom and middle of the deep concrete layer, which can eliminate deep air bubbles and drain water, ensuring that the core area of the structure is dense. The higher-position second vibrator 10 moves ahead and acts on the shallow layer, which can treat the surface and near-surface concrete in time, making up for the problem of insufficient coverage of the shallow layer by the lower-position vibrator. Therefore, the two work together to form full-depth vibration coverage of the deep and shallow layers. Especially in areas with dense reinforcement, the division of labor between the high and low positions can reduce local leakage caused by reinforcement obstruction. Two opposing ultrasonic sensors 20 are installed at an angle on one side of the frame 5. The ultrasonic sensors 20 are electrically connected to the pusher 4 and the lifting component 6 through the controller.
[0041] In the initial state, the lower-position first vibrator 8 and the higher-position second vibrator 10 can vibrate the concrete. The drive frame 1 can drive the pusher 4 to move, thereby driving the first vibrator 8 and the second vibrator 10 to move slowly. When the lower-position first vibrator 8 is about to approach the reinforcing steel, the ultrasonic sensor 20 will detect the presence of reinforcing steel in the direction of movement. At this time, the controller (the controller is existing technology and is not shown in the figure) lifter 6 drives the first moving seat 7 to move upward, thereby driving the first vibrator 8 to move upward. Since the first moving seat 7 and the second moving seat 9 are connected by transmission, when the first moving seat 7 moves upward, the higher-position second moving seat 9 will move downward. Because there is a gap between the first vibrator 8 and the second vibrator 10, the second vibrator 10 has passed the reinforcing steel and inserted into the concrete. The first vibrator 8 moves upward with the first moving seat 7 to the shallow area of the concrete. At the same time, the pusher 4 causes the frame 5 to rotate, thereby driving the first vibrator 8 and the second vibrator 10 to rotate, realizing the role interchange of the first vibrator 8 and the second vibrator 10.
[0042] The primary and secondary vibration zones can be flexibly switched according to the distribution of reinforcing bars, and the deformation of reinforcing bars or damage to the vibrator caused by hard collisions can be avoided. In traditional vibration operations, when encountering reinforcing bars, the vibrator needs to be stopped and restarted frequently. After stopping, the position needs to be manually adjusted and reinserted, resulting in a high-energy-consuming cycle of repeated starting and stopping. By using the ultrasonic sensor 20 to predict and the first vibrator 8 and the second vibrator 10 to work alternately, a continuous operation mode is achieved where the machine does not stop when encountering reinforcing bars, and only the working parts are switched. When the first vibrator 8 moves upward to avoid the reinforcement, the second vibrator 10 has already started vibrating synchronously, avoiding the instantaneous high energy consumption of frequent starting and stopping of a single device, and achieving the effect of energy saving.
[0043] In the initial state, the lower-position first vibrator 8 and the higher-position second vibrator 10 can vibrate the concrete. The drive frame 1 can drive the pusher 4 to move, thereby driving the first vibrator 8 and the second vibrator 10 to move slowly. When the lower-position first vibrator 8 is about to approach the reinforcing steel, the ultrasonic sensor 20 will detect the presence of reinforcing steel in the direction of movement. At this time, the controller (the controller is existing technology and is not shown in the figure) lifter 6 drives the first moving seat 7 to move upward, thereby driving the first vibrator 8 to move upward. Since the first moving seat 7 is connected to the second moving seat 9, when the first moving seat 7 moves upward, the higher-position second moving seat 9 will move downward. Because there is a gap between the first vibrator 8 and the second vibrator 10, the second vibrator 10 has passed the reinforcing steel and inserted into the concrete. The first vibrator 8 moves upward with the first moving seat 7 to the shallow area of the concrete. At the same time, the pusher 4 causes the four frames 5 to rotate, thereby driving the first vibrator 8 and the second vibrator 10 to rotate, realizing the role interchange of the first vibrator 8 and the second vibrator 10.
[0044] Furthermore, the oscillating component 3 causes the pushing component 4 to oscillate slightly during its slow movement. The slow movement ensures that the first vibrator 8 and the second vibrator 10 have sufficient time to act in each area, while the slight oscillation allows the vibration energy to gradually diffuse to the periphery, transmitting vibration from the center of the first vibrator 8 and the second vibrator 10 to the edge. This avoids uneven vibration caused by a quick sweep, thus significantly improving the vibration effect of the concrete. Therefore, it can achieve a continuous action of switching the positions of the first vibrator 8 and the second vibrator 10 (the first vibrator 8 rises and the second vibrator 10 inserts), avoiding direct contact between the first vibrator 8 or the second vibrator 10 with the reinforcing bars, which could lead to damage or jamming. At the same time, the pushing component 4 enables the first vibrator 8 or the second vibrator 10 to interchange positions, ensuring that the switching logic can be repeated when encountering reinforcing bars again, completely solving the problem of traditional vibrators being forced to stop due to reinforcing bars blocking the machine.
[0045] like Figure 2 As shown, the drive frame 1 includes a base 11 and a first bracket 12 fixed to one side of the base 11. The first bracket 12 is stably connected to the base 11 by welding. A motor 13 is fixedly installed at one end of the first bracket 12. A screw 14 is rotatably connected inside the first bracket 12 and is fixedly connected to the output end of the motor 13. A second bracket 15 is fixedly installed on one side of the base 11. A slide rod 16 is fixedly installed inside the second bracket 15. A movable plate 17 is threadedly connected to the surface of the screw 14 and is slidably connected to the first bracket 12, the second bracket 15 and the slide rod 16. The motor 13 can drive the screw 14 to rotate, and the screw 14 can drive the movable plate 17 to move, thereby driving the pusher 4 to move back and forth. The slide rod 16 limits the movement of the movable plate 17 to prevent it from rotating with the screw 14, ensuring that the movable plate 17 can move continuously and stably.
[0046] like Figure 3 and Figures 6-8 As shown, a shaft 51 is fixedly installed at one end of the frame 5. The shaft 51 is rotatably connected to the base plate 41. A first gear 52 is fixedly installed at one end of the shaft 51, and a first toothed plate 45 is meshed with the first gear 52. Slide grooves 53 are opened inside both sides of the frame 5. A support rod 54 is rotatably connected inside the frame 5. A second gear 55 is fixedly installed on the surface of the support rod 54. The output end of the electric push rod 43 can drive the first toothed plate 45 to move. Since the first toothed plate 45 is meshed with the first gear 52, the movement of the first toothed plate 45 can drive the first gear 52 to rotate until the frame 5 rotates 360° to interchange the positions of the first vibrator 8 and the second vibrator 10.
[0047] The lifting component 6 includes a cylinder 61 and an annular frame 62 fixed to one end of the cylinder 61. The annular frame 62 consists of four rings. The output end of the cylinder 61 is connected through to one side of the rectangular plate 413. Two contact rods 63 are fixedly installed on one side of the annular frame 62, and both contact rods 63 are slidably connected to two strip plates 414. An arc-shaped groove 64 is provided inside the annular frame 62. The annular frame 62 can be moved through the output end of the cylinder 61, thereby adjusting the height of the annular frame 62.
[0048] The first movable seat 7 includes an L-shaped plate 71 and a second toothed plate 72 fixed to one side of the L-shaped plate 71. The L-shaped plate 71 is slidably connected to the frame 5, and the second toothed plate 72 is meshed with the second gear 55. First limiting blocks 73 are fixedly installed on both sides of the L-shaped plate 71, and both first limiting blocks 73 are slidably connected to the slide groove 53. The movement of the L-shaped plate 71 can be limited by the cooperation of the two first limiting blocks 73 and the slide groove 53, preventing the L-shaped plate 71 from detaching from the frame 5. A first damper 74 is fixedly installed at one end of the L-shaped plate 71, and the first vibrator 8 is fixedly connected to the first damper 74. The first damper 74 attenuates the vibration amplitude transmitted by the first vibrator 8 through damping materials such as silicone or metal damping sheets, so as to avoid damage to the connection structure or affect the stability of the equipment due to vibration. A T-shaped rod 75 is fixedly installed at the other end of the L-shaped plate 71, and the T-shaped rod 75 is slidably connected to the arc groove 64.
[0049] When the output end of cylinder 61 drives the ring frame 62 to move upward, the L-shaped plate 71 can be moved through the connection of T-shaped rod 75, thereby driving the first vibrator 8 to move upward. When the frame 5 rotates, it can drive the T-shaped rod 75 to move inside the arc groove 64, so that the T-shaped rod 75 rotates around the shaft 51. On the one hand, one cylinder 61 can drive the four first vibrators 8 to move, which can play an energy-saving role. On the other hand, the movement of T-shaped rod 75 inside the arc groove 64 can limit the L-shaped plate 71 and prevent the L-shaped plate 71 from moving downward automatically due to gravity.
[0050] The second movable seat 9 includes a vertical plate 91 and a third toothed plate 92 fixed to one side of the vertical plate 91. The vertical plate 91 is slidably connected to the frame 5, and the third toothed plate 92 is meshed with the second gear 55. Second limiting blocks 93 are fixedly installed on both sides of the vertical plate 91, and both second limiting blocks 93 are slidably connected to the slide groove 53. The movement of the vertical plate 91 can be limited by the cooperation of the two second limiting blocks 93 and the slide groove 53 to prevent the vertical plate 91 from detaching from the frame 5. A second damper 94 is fixedly installed at one end of the vertical plate 91. The second damper 94 attenuates the vibration amplitude transmitted by the second vibrator 10 through damping materials such as silicone or metal damping sheets to avoid damage to the connection structure or affect the stability of the equipment due to vibration. The second vibrator 10 is fixedly connected to the second damper 94.
[0051] When the output end of cylinder 61 drives the ring frame 62 to move upward, the L-shaped plate 71 can be moved through the connection of T-shaped rod 75, thereby driving the first vibrator 8 to move upward. At this time, since the second toothed plate 72 and the third toothed plate 92 are both meshed with the second gear 55, when the second toothed plate 72 moves upward, the rotation of the second gear 55 drives the third toothed plate 92 to move downward, thereby driving the second vibrator 10 to move downward, realizing the interchange of the positions of the first vibrator 8 and the second vibrator 10.
[0052] To address the technical problem of a small vibration range and the tendency to miss areas during vibration, such as... Figures 3-6 As shown, the following preferred technical solutions are provided:
[0053] The swinging component 3 includes a fixed frame 31 and a serpentine track 32 fixed to one side of the fixed frame 31. Limiting grooves 33 are provided on both sides of the serpentine track 32. The serpentine track 32 and the limiting grooves 33 can play a limiting role. The serpentine track 32 can force the running component to continuously change the direction of movement during the movement. When the pushing component 4 enters another reverse bending section from one curved section of the serpentine track 32, a lateral offset force is generated, which in turn drives the pushing component 4 connected to it to form a small swinging effect. No additional power is needed to drive the swinging action. The expansion of the vibration range can be achieved simply by the shape of the serpentine track 32, which can reduce the number of power sources and reduce energy consumption.
[0054] The pusher 4 includes a base plate 41 and a housing 42 fixed to one side of the base plate 41. An electric push rod 43 is fixedly installed on one side of the housing 42. A mounting shell 44 is fixedly installed on the surface of the electric push rod 43 and is fixedly connected to the housing 42. The mounting shell 44 is connected to the housing 42 by bolts, so the electric push rod 43 can be easily disassembled and installed. A first toothed plate 45 is slidably connected inside the housing 42. A mounting block 46 is fixedly installed on one side of the first toothed plate 45 and the output end of the electric push rod 43 is fixedly connected to the mounting block 46. A T-shaped block 47 is fixedly installed on the surface of the housing 42 and is slidably connected to the moving plate 17. The design of the T-shaped block 47 allows the housing 42 to slide more stably inside the moving plate 17. A roller 48 is rotatably connected to one side of the T-shaped block 47. The roller 48 can reduce friction and allow the T-shaped block 47 to move better inside the moving plate 17. The roller 48 is in contact with the inside of the moving plate 17.
[0055] A concave plate 411 is fixedly installed at one end of the base plate 41. The concave plate 411 is in contact with the serpentine track 32. Rollers 412 are rotatably connected to both sides of the concave plate 411, and the rollers 412 are in contact with the limiting groove 33. A rectangular plate 413 is fixedly installed on one side of the base plate 41. Two strip plates 414 are installed on one side of the base plate 41 near the rectangular plate 413. When the screw 14 can drive the moving plate 17 to move, it can drive the base plate 41 and the housing 42 to move back and forth. At the same time, when the base plate 41 moves, the rollers 412 move inside the limiting groove 33. With the limiting and guiding of the serpentine track 32, the base plate 41 moves slowly while generating a small left and right swing, thus expanding the vibration range and reducing the area of missed vibration.
[0056] Traditional immersion vibrators rely solely on vertical insertion and linear movement, limiting the vibration range to a circular area around the vibrator. If the movement path is not properly controlled, it can easily lead to missed vibrations in areas such as gaps between reinforcing bars and corners of components. Small left-right swings can expand the effective area of the first vibrator 8 and the second vibrator 10 from a circular area to a fan-shaped area, with greater overlap in the coverage of adjacent vibration points. This is especially suitable for areas with dense reinforcing bars or complex components, as it can fill the gaps during linear movement and prevent honeycombing and pitting caused by missed vibrations.
[0057] To further illustrate the above embodiments, the present invention also provides an implementation method, a method of using a precast bridge slab production apparatus, comprising the following steps:
[0058] Step 1: In the initial state, the low-position first vibrator 8 and the high-position second vibrator 10 can vibrate the concrete, and the drive frame 1 can drive the pusher 4 to move slowly. The low-position first vibrator 8 vibrates the deep layer of concrete, while the high-position second vibrator 10 moves ahead and acts on the shallow layer. The two work together to form full-depth vibration coverage of the deep and shallow layers.
[0059] Step 2: When the first vibrator 8 is about to approach the steel bar, the ultrasonic sensor 20 will detect the presence of steel bar in the direction of movement. By predicting the movement through the ultrasonic sensor 20 and alternating between the first vibrator 8 and the second vibrator 10, the roles of the first vibrator 8 and the second vibrator 10 can be interchanged. The primary and secondary vibration areas can be flexibly switched according to the distribution of steel bars, and the deformation of steel bars or damage to the first vibrator 8 caused by hard collisions can be avoided.
[0060] Step 3: The oscillating component 3 causes the pushing component 4 to oscillate slowly during the movement. The slow movement ensures that the first vibrator 8 and the second vibrator 10 have sufficient time to act in each area, while the small oscillation allows the vibration energy to gradually diffuse to the periphery. The vibration is gradually transmitted from the center of the first vibrator 8 and the second vibrator 10 to the edge, avoiding uneven vibration caused by sweeping over the area due to rapid movement, and thus fully improving the vibration effect of the concrete.
[0061] Step 4: By using the ultrasonic sensor 20 to predict and the first vibrator 8 and the second vibrator 10 to work alternately, a continuous operation mode is achieved where the machine does not stop when encountering steel bars, but only the working parts are switched. When the first vibrator 8 moves upward to avoid the steel bars, the second vibrator 10 has already started vibrating synchronously, which avoids the instantaneous high energy consumption of frequent start-stop of a single device and can achieve the effect of energy saving.
[0062] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.
[0063] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A device for the production of precast bridge slabs, comprising a drive carriage (1), characterised in that: The drive frame (1) has a mold (2) fixedly installed inside. A swinging component (3) is fixedly installed on one side of the drive frame (1). A pusher (4) is slidably connected to the side of the drive frame (1) near the swinging component (3). One end of the pusher (4) is slidably connected to the swinging component (3). Several frames (5) are provided at the bottom of the pusher (4). A lifting component (6) is fixedly installed on one side of the pusher (4). A first moving seat (7) is slidably connected to one side of the frame (5). The first moving seat (7) is rotatably connected to the lifting component (6). A first vibrator (8) is installed at one end of the first moving seat (7). A second moving seat (9) is slidably connected to the other side of the frame (5). The second moving seat (9) is installed at a higher position than the first moving seat (7). The first moving seat (7) is connected to the second moving seat (9) in a transmission connection. A second vibrator (10) is installed at one end of the second moving seat (9). Two opposing ultrasonic sensors (20) are installed at an angle on one side of the frame (5). The ultrasonic sensors (20) are electrically connected to the pusher (4) and the lifting component (6) through the controller. The swing component (3) includes a fixed frame (31) and a serpentine track (32) fixed on one side of the fixed frame (31). Limiting grooves (33) are provided on both the upper and lower sides of the serpentine track (32).
2. The apparatus for producing a precast bridge slab according to claim 1, wherein: The drive frame (1) includes a base (11) and a first bracket (12) fixed on one side of the base (11). A motor (13) is fixedly installed at one end of the first bracket (12). A screw (14) is rotatably connected inside the first bracket (12), and the screw (14) is fixedly connected to the output end of the motor (13). A second bracket (15) is fixedly installed on one side of the base (11). A slide rod (16) is fixedly installed inside the second bracket (15). A movable plate (17) is threadedly connected to the surface of the screw (14), and the movable plate (17) is slidably connected to the first bracket (12), the second bracket (15), and the slide rod (16).
3. The precast bridge slab production apparatus according to claim 2, characterized in that: The pusher (4) includes a base plate (41) and a housing (42) fixed to one side of the base plate (41). An electric push rod (43) is fixedly installed on one side of the housing (42). An mounting shell (44) is fixedly installed on the surface of the electric push rod (43), and the mounting shell (44) is fixedly connected to the housing (42). A first toothed plate (45) is slidably connected inside the housing (42). An mounting block (46) is fixedly installed on one side of the first toothed plate (45), and the output end of the electric push rod (43) is fixedly connected to the mounting block (46). A T-shaped block (47) is fixedly installed on the surface of the housing (42), and the T-shaped block (47) is slidably connected to the moving plate (17). A roller (48) is rotatably connected on one side of the T-shaped block (47), and the roller (48) is in contact with the inside of the moving plate (17).
4. The precast bridge slab production apparatus according to claim 3, characterized in that: A concave plate (411) is fixedly installed at one end of the base plate (41). The concave plate (411) is in contact with the serpentine track (32). Rollers (412) are rotatably connected to both sides of the concave plate (411), and the rollers (412) are in contact with the limiting groove (33). A rectangular plate (413) is fixedly installed on one side of the base plate (41). Two strip plates (414) are installed on one side of the base plate (41) near the rectangular plate (413).
5. The precast bridge slab production apparatus according to claim 4, characterized in that: A shaft (51) is fixedly installed at one end of the frame (5), and the shaft (51) is rotatably connected to the base plate (41). A first gear (52) is fixedly installed at one end of the shaft (51), and a first toothed plate (45) meshes with the first gear (52). Slide grooves (53) are provided inside both sides of the frame (5), and a support rod (54) is rotatably connected inside the frame (5). A second gear (55) is fixedly installed on the surface of the support rod (54).
6. The precast bridge slab production apparatus according to claim 5, characterized in that: The lifting component (6) includes a cylinder (61) and an annular frame (62) fixed to one end of the cylinder (61). The output end of the cylinder (61) is connected through to one side of the rectangular plate (413). Two contact rods (63) are fixedly installed on one side of the annular frame (62), and both contact rods (63) are slidably connected to two strip plates (414). An arc groove (64) is opened inside the annular frame (62).
7. The precast bridge slab production apparatus according to claim 6, characterized in that: The first movable seat (7) includes an L-shaped plate (71) and a second toothed plate (72) fixed on one side of the L-shaped plate (71). The L-shaped plate (71) is slidably connected to the frame (5), and the second toothed plate (72) is meshed with the second gear (55). First limiting blocks (73) are fixedly installed on both sides of the L-shaped plate (71), and both first limiting blocks (73) are slidably connected to the slide groove (53). A first damper (74) is fixedly installed at one end of the L-shaped plate (71), and the first vibrator (8) is fixedly connected to the first damper (74). A T-shaped rod (75) is fixedly installed at the other end of the L-shaped plate (71), and the T-shaped rod (75) is slidably connected to the arc groove (64).
8. The precast bridge slab production apparatus according to claim 7, characterized in that: The second movable seat (9) includes a vertical plate (91) and a third toothed plate (92) fixed on one side of the vertical plate (91). The vertical plate (91) is slidably connected to the frame (5). The third toothed plate (92) is meshed with the second gear (55). Second limiting blocks (93) are fixedly installed on both sides of the vertical plate (91), and both second limiting blocks (93) are slidably connected to the slide groove (53). A second damper (94) is fixedly installed at one end of the vertical plate (91). The second vibrator (10) is fixedly connected to the second damper (94).
9. A method of using the precast bridge slab production apparatus according to any one of claims 1-8, characterized in that, Includes the following steps: S1: In the initial state, the low-position first vibrator (8) and the high-position second vibrator (10) vibrate the concrete, and the drive frame (1) can drive the pusher (4) to move slowly. The low-position first vibrator (8) vibrates the deep layer of the concrete, and the high-position second vibrator (10) moves ahead and acts on the shallow layer. The two work together to form a full-depth vibration coverage of the deep and shallow layers. S2: When the first vibrator (8) is about to approach the steel bar, the ultrasonic sensor (20) will detect the presence of steel bar in the direction of movement. By using the ultrasonic sensor (20) to predict and the first vibrator (8) and the second vibrator (10) to work alternately, the roles of the first vibrator (8) and the second vibrator (10) can be interchanged. The main and secondary vibration areas can be flexibly switched according to the distribution of steel bars, and the deformation of steel bars or damage to the first vibrator (8) caused by hard collisions can be avoided. S3: The oscillating component (3) causes the pushing component (4) to oscillate slowly during the movement. The slow movement ensures that the first vibrator (8) and the second vibrator (10) have sufficient time to act in each area, while the small oscillation allows the vibration energy to gradually diffuse to the periphery. The vibration is gradually transmitted from the center of the first vibrator (8) and the second vibrator (10) to the edge, avoiding uneven vibration caused by sweeping over due to rapid movement, and fully improving the vibration effect of concrete. S4: By using the ultrasonic sensor (20) to predict and the first vibrator (8) and the second vibrator (10) to work alternately, a continuous operation mode is achieved where the machine does not stop when encountering steel bars, and only the working parts are switched. When the first vibrator (8) moves upward to avoid the steel bars, the second vibrator (10) has already started vibrating synchronously, which avoids the instantaneous high energy consumption of frequent start-stop of a single device and can achieve the effect of energy saving.