Beam and slab prefabrication integrated production line

Abstract

The beam and slab prefabrication integrated production line comprises a steel bar machining unit, a movable mold table, a mold closing mechanism, a concrete pouring unit, a steam curing unit and a finished product transferring unit which are sequentially arranged along a ground rail. A T-shaped steel reinforcement framework is formed by the steel reinforcement machining units, a pouring area is defined by the strip-shaped mold table, the T-shaped mold plate and the side mold plate through the unique structural design of the movable mold table, and the side mold plate can move along the oblique sliding base. The mold closing mechanism realizes mold closing through a hydraulic rod; the finished product transfer unit transfers finished products through cooperation of a hydraulic supporting rod and a transfer trolley. The production line effectively solves the problems of large demolding friction, high energy consumption, low efficiency and the like of a traditional T-shaped beam plate prefabrication production line, can improve the prefabrication quality and production efficiency of the T-shaped beam plate, and is suitable for large-scale bridge engineering construction.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of precast beam slab, and particularly relates to a beam slab precast integrated production line. BACKGROUND

[0002] In modern bridge engineering construction, the T-shaped beam slab as an important load-bearing component, its precast quality directly affects the safety and durability of the bridge. At present, the traditional T-shaped beam slab precast production line has significant defects in the demolding link. Since the T-shaped beam slab is poured and shaped, there are both vertical contact surface and horizontal contact surface between the mold and the T-shaped beam slab. The existing vertical or horizontal demolding mode inevitably causes friction between the mold and the surface of the T-shaped beam slab in the separation process. Such friction not only causes the concrete surface to have defects such as scratches and cracks, reducing the appearance quality of the T-shaped beam slab, but also may damage the internal structure of the concrete, weakening its carrying capacity. In addition, in order to overcome the frictional resistance, the demolding equipment needs to provide a large power, resulting in increased energy consumption and intensified equipment wear and tear, and at the same time, the demolding efficiency is low, which is difficult to meet the needs of large-scale engineering construction. SUMMARY

[0003] In view of the problems and deficiencies of the prior art, the present application provides a beam slab precast integrated production line, which effectively solves the demolding problem of the traditional T-shaped beam slab precast production line through innovative design of each unit structure and function, and comprehensively improves the precast quality and production efficiency of the T-shaped beam slab.

[0004] The present application is realized by the following technical solutions: A beam slab precast integrated production line, comprising a steel bar processing unit, a movable mold table, a mold closing mechanism, a concrete pouring unit, a steam curing unit and a finished product transfer unit arranged in sequence along the extension direction of the ground rail. The steel bar processing unit processes the steel bar to form a T-shaped steel bar framework. The steel bar processing unit processes the steel bar through specialized processing equipment and process, such as straightening, cutting, bending and welding, to form a T-shaped steel bar framework that meets the design requirements, laying a foundation for the internal structure of the T-shaped beam slab.

[0005] The mobile mold table is one of the core components of the production line, and its structure design is extremely innovative. The mobile mold table includes a mobile platform, a strip-shaped mold table fixed at the center of the mobile platform, two inclined slides located on both sides of the strip-shaped mold table, two oppositely arranged T-shaped mold plates, and two oppositely arranged side mold plates. A transfer groove is formed in the strip-shaped mold table, and the strip-shaped mold table, the T-shaped mold plate, and the side mold plate jointly form a pouring area for accommodating a T-shaped steel reinforcement framework. The side mold plate is slidably connected to the inclined slide through a support frame and can move along the extension direction of the inclined slide from the center of the mobile platform to both sides, and the height of the inclined slide gradually decreases. This design of inclined slide breaks the limitation of traditional vertical or horizontal demolding. When demolding, the side mold plate can slide downward along the inclined slide, eliminating the friction between the mold and the T-shaped beam, effectively avoiding problems such as surface scratches and scratches on the T-shaped beam slab, and improving the appearance quality of the T-shaped beam slab. At the same time, by eliminating the friction, the power demand of the demolding equipment is reduced, the energy consumption and equipment wear are reduced, and the demolding efficiency is improved.

[0006] The mold closing mechanism is fixed on both sides of the ground rail and symmetrically arranged relative to the ground rail, and includes a support steel wall and a hydraulic rod hingedly installed between the support steel wall and the support frame. During mold closing, the hydraulic rod is precisely controlled to extend and retract, pushing the side mold plate to move along the inclined slide until it is tightly combined with the T-shaped mold plate and the strip-shaped mold table to form a closed pouring area. The stable and controllable mold closing power provided by the hydraulic rod can ensure that the mold remains tightly combined and prevent slurry leakage, ensuring the forming precision and quality of the T-shaped beam slab.

[0007] The finished product transfer unit includes a hydraulic support rod installed in the transfer groove, a work-shaped bearing plate fixed to the top of the hydraulic support rod, a transfer trolley, and a traveling crane. When the T-shaped beam slab is poured, the hydraulic support rod is in an extended state, making the surface of the work-shaped bearing plate flush with the surface of the strip-shaped mold table. After the T-shaped beam slab is poured and cured, the hydraulic support rod is retracted, the work-shaped bearing plate is removed, and the transfer trolley is installed at the bottom of the T-shaped beam slab. Subsequently, the lifting rope of the traveling crane is installed into the lifting hole of the transfer trolley, achieving the lifting and transfer of the entire T-shaped beam slab. The unique structure design of the work-shaped bearing plate has higher strength and stability than ordinary bearing plates, and can better support the T-shaped beam slab.

[0008] Further, the oblique sliding seat is in U shape and is provided with two groups of inclined plates at the top, the bottom of the support frame is provided with a sliding plate abutting to the inclined plates, the width of the sliding plate is greater than that of the inclined plate, the sliding plate is further provided with a backing plate and an anti-disengagement plate at both sides, the thickness of the backing plate is greater than that of the inclined plate, the anti-disengagement plate is located at the side of the inclined plate away from the sliding plate, and a fastening bolt penetrates through the sliding plate, the backing plate and the anti-disengagement plate. The structure design greatly enhances the stability and reliability of the connection between the side mold plate and the oblique sliding seat. The width of the sliding plate is greater than that of the inclined plate, which provides a larger contact area, so that the side mold plate is more evenly stressed during movement; the thickness difference between the backing plate and the inclined plate provides a sliding gap. The anti-disengagement plate effectively prevents the sliding plate from disengaging from the inclined plate during movement, ensuring that the demolding process is safe and smooth, and further improving the safety and product quality of production.

[0009] Further, the heads and tails of the sliding plate and the anti-disengagement plate are tilted away from the inclined plate. The tilted structure reduces direct friction between the sliding plate and the edge of the inclined plate, reduces the degree of wear, prevents small protrusions on the surface of the inclined plate from blocking the sliding of the sliding plate, prolongs the service life of the sliding plate and the oblique sliding seat, and improves the durability and stability of the equipment.

[0010] Further, the two ends of the strip-shaped mold table are provided with steps, the steps are provided with backing blocks through limiting bolts, the height of the backing blocks is flush with the top surface of the strip-shaped mold table, the distance between the side wall of the backing block and the strip-shaped mold table is equal to the thickness of the T-shaped mold plate, the bottom of the T-shaped mold plate has an arc-shaped bottom wall, and the arc-shaped bottom wall is located below the top surface of the strip-shaped mold table, and the top of the T-shaped mold plate is provided with a lifting ring. The structure design realizes the accurate positioning and installation of the T-shaped mold plate on the strip-shaped mold table, the cooperation of the limiting bolt and the backing block ensures the accuracy of the installation position of the T-shaped mold plate, and guarantees the dimensional accuracy of the pouring area; the arc-shaped bottom wall design of the bottom of the T-shaped mold plate makes it easier to install the T-shaped mold plate to the area between the side wall of the backing block and the strip-shaped mold table. The setting of the lifting ring facilitates the lifting and dismounting of the T-shaped mold plate, improves the work efficiency of mold installation and replacement, and reduces the manual operation time and labor intensity.

[0011] Further, the side walls of the two side mold plates are each provided with a connecting plate aligned with each other, the connecting plate is provided with a U-shaped slot, a limiting pull rod is installed between the two connecting plates, the limiting pull rod can prevent the side mold plate from moving away from the pouring area, and a hydraulic jack is further installed on the moving platform, and the hydraulic jack is located directly below the support frame. The limiting pull rod is inserted into the U-shaped slot of the connecting plate to horizontally limit the side mold plate, effectively preventing the side mold plate from moving outward due to the side pressure of the concrete during the concrete pouring process, and ensuring the stability of the shape and size of the pouring area; the hydraulic jack provides vertical support force for the side mold plate, and according to the pressure changes at different stages during the concrete pouring process, the support force of the side mold plate can be adjusted in real time through the hydraulic jack, ensuring the stability of the side mold plate during the pouring process, thereby ensuring the forming quality of the T-shaped beam plate.

[0012] Further, the inner side of the side formwork is also provided with a limiting groove, and a limiting plate is inserted and installed in the limiting groove. The limiting plate is located outside the pouring area and abuts against the T-shaped formwork. The limiting plate further limits the position of the T-shaped formwork. During the concrete pouring process, the limiting plate can ensure that the T-shaped formwork maintains an accurate position, prevents the T-shaped formwork from being slightly displaced, and ensures the shape and size accuracy of the pouring area. At the same time, the limiting plate abuts against the T-shaped formwork, which provides a better positioning reference for the T-shaped steel reinforcement framework, helps to improve the installation accuracy of the T-shaped steel reinforcement framework in the pouring area, and further improves the overall quality of the T-shaped beam slab.

[0013] Further, a demolding vibrator is also installed on the side formwork. The demolding vibrator can apply vibration to the side formwork to assist in separating the T-shaped beam slab from the side formwork. During the demolding process, the vibration generated by the demolding vibrator can effectively reduce the adsorption force and friction force between the T-shaped beam slab and the side formwork, and reduce the demolding resistance. Especially for some cases where the concrete is tightly bonded to the side formwork, the vibration of the demolding vibrator can make the T-shaped beam slab and the side formwork more easily separated, making the demolding process smoother, greatly improving the demolding efficiency, shortening the production cycle, and also reducing the risk of damage to the T-shaped beam slab due to difficult demolding.

[0014] Further, the production line also includes a central control system, which is in control connection with the steel bar processing unit, the movable formwork, the form closing mechanism, the concrete pouring unit, the steam curing unit, and the finished product transfer unit. The central control system uses advanced automatic control technology and algorithms to realize real-time monitoring and accurate control of each unit of the entire production line. By presetting production parameters and process flow, the central control system can automatically coordinate the operation of each unit, such as accurately controlling the steel bar processing parameters of the steel bar processing unit, the moving path and speed of the movable formwork, the form closing force and time of the form closing mechanism, the pouring speed and volume of the concrete pouring unit, the curing temperature and time of the steam curing unit, and the transfer sequence of the finished product transfer unit, etc. This not only improves the degree of automation of production, reduces manual intervention, and reduces the probability of human operation errors, but also allows timely adjustment of the operating parameters of each unit according to the actual situation during the production process, optimizes the production process, and improves the production efficiency. At the same time, it is convenient for production management personnel to monitor and manage the entire production process, realizes the informatization and intelligentization of the production process.

[0015] Further, the concrete pouring unit includes a torpedo tank for storing and transporting concrete and a distributing machine capable of uniformly pouring concrete into the pouring area. This combination realizes efficient transportation and accurate pouring of concrete. The large storage and transportation capacity of the torpedo tank ensures continuous supply of concrete. The distributing machine can flexibly adjust the distribution method and speed according to the shape and size of the pouring area, ensuring the uniformity and compactness of concrete pouring, avoiding pouring defects such as honeycomb and pitted surface, and ensuring the pouring quality of the T-shaped beam slab. The steam curing unit can perform primary mold curing and secondary demolding curing on the T-shaped beam slab. The primary mold curing can provide a suitable temperature and humidity environment for the T-shaped beam slab after pouring, accelerate the early strength growth of the concrete, and improve the setting quality of the concrete. The secondary demolding curing further cures the T-shaped beam slab after demolding to ensure that the strength and performance of the T-shaped beam slab meet the design requirements. This double curing method can provide targeted curing conditions according to the needs of the T-shaped beam slab at different stages, effectively shortening the curing time of the T-shaped beam slab, improving the production efficiency, and ensuring the quality stability of the T-shaped beam slab.

[0016] Further, the transfer trolley can move to the transfer groove. The bottom of the transfer trolley is provided with steel wheels. The length of the transfer trolley is greater than the width of the abutting part of the T-shaped beam slab to the transfer trolley, and the part of the transfer trolley protruding from the T-shaped beam slab is provided with a lifting hole. The steel wheels at the bottom of the transfer trolley can move flexibly on the ground, facilitating the movement of the T-shaped beam slab. The length of the transfer trolley is greater than the width of the abutting part of the T-shaped beam slab, and the lifting hole is provided on the part protruding from the T-shaped beam slab, so that the transfer trolley can stably carry the T-shaped beam slab and be conveniently lifted by the traveling crane. During lifting, the lifting hole can accurately hook the lifting hook of the traveling crane, ensuring the safety and reliability of the lifting process, improving the flexibility and efficiency of the T-shaped beam slab transfer, and facilitating the transfer of the T-shaped beam slab to different storage areas or subsequent processing positions.

[0017] The beneficial effects of the present application are: The beam slab prefabrication integrated production line of the present application realizes a technical breakthrough in the field of T-shaped beam slab prefabrication through systematic innovation design and multi-unit collaborative work. The overall beneficial effects are reflected in multiple key aspects, which can effectively solve the drawbacks of traditional production lines and bring significant value to bridge engineering construction.

[0018] Quality improvement: From the forming source of T-beam slab to the final product, the production line guarantees the product quality in all aspects. In the steel bar processing unit, specialized equipment and precise process ensure the accurate size and stable structure of T-shaped steel skeleton, providing reliable internal support for T-beam slab. The design of mobile mold table is particularly critical. The oblique sliding seat cooperates with the oblique demolding mode of the side mold plate, greatly reducing the friction between the mold and the T-beam slab, avoiding the damage and scratches on the concrete surface caused by friction, making the T-beam slab surface smooth and improving the appearance quality. At the same time, the reduced friction force avoids the damage of the internal structure of the concrete due to demolding, ensuring that the bearing capacity is not affected. The primary mold curing and secondary demolding curing double mechanism of the steam curing unit provides precise curing according to the different needs of T-beam slab at different stages, accelerates the growth of concrete strength, improves the coagulation quality of concrete, and ensures that the strength and performance of T-beam slab meet the design requirements, thus guaranteeing the overall quality of T-beam slab from multiple aspects.

[0019] Efficiency improvement: The efficient cooperation and innovative design of each unit of the production line significantly improve the production efficiency. The automatic processing equipment of the steel bar processing unit can quickly complete the straightening, cutting, bending, and welding of steel bars, greatly shortening the production time of steel skeleton compared to traditional manual processing. The mobile mold table moves quickly between units, reducing the waiting time for process connection. Its unique demolding design reduces the demolding resistance and cooperates with the demolding vibrator to make the demolding process smoother, effectively shortening the demolding time. The hydraulic drive of the mold closing mechanism makes the operation simple and fast, and can quickly complete the assembly of the mold. The combination of the torpedo tank and the distributor in the concrete pouring unit realizes efficient transportation and uniform pouring of concrete, avoiding downtime and rework caused by insufficient concrete supply or uneven pouring. The steam curing unit adjusts the curing parameters automatically according to the strength growth data of T-beam slab through the intelligent temperature control system, shortens the curing period under the premise of ensuring quality. The combination of the transfer car and the gantry crane in the finished product transfer unit can quickly and efficiently transfer T-beam slab to the designated location, reducing the waiting time for finished product accumulation. The real-time monitoring and automatic coordination of the central control system on the entire production line make the units work closely together, realize seamless connection of the production process, further improve the overall production efficiency, and meet the rapid production demand of T-beam slab for large-scale engineering construction.

[0020] Cost control: The production line realizes effective control of cost through various ways. In terms of energy consumption, due to the reduction of frictional resistance in the demolding process, the power required by the demolding equipment is greatly reduced, thereby reducing the power consumption; at the same time, the efficient operation and reasonable scheduling of each unit equipment avoid the waste of energy and reduce the production energy consumption cost. In terms of equipment maintenance, the reduced friction and stable operation of the equipment reduce the degree of equipment wear and tear, prolong the service life of the equipment, reduce the frequency of equipment repair and replacement, and reduce the equipment maintenance cost. In addition, the automation and intelligence level of the production line is improved, reducing the manual operation link and reducing the labor cost; at the same time, precise production control reduces the waste of raw materials, further reduces the production cost, and improves the economic benefit of the enterprise.

[0021] Intelligent management: The introduction of the central control system enables the production line to realize highly informationized and intelligent management. By presetting the production parameters and process flow, the system can automatically coordinate the operation of each unit without frequent manual intervention, reducing the probability of human operation errors and improving the stability and reliability of the production process.

[0022] Adaptability and flexibility: The production line has good adaptability and flexibility, which can meet the prefabrication needs of different projects and different specifications of T-shaped beam plates. In the steel bar processing unit, the specifications and processing technology of the steel bars can be flexibly adjusted according to the design requirements of the T-shaped beam plate; the T-shaped beam plate of the mobile mold table and the side mold plate can be replaced according to the size of the T-shaped beam plate, and the pouring area size can be accurately adjusted by adjusting the limiting bolts, pads and limiting plates and other components; the concrete pouring unit can adjust the operating parameters of the torpedo tank and the distributor according to the characteristics of the concrete and the pouring requirements; the steam curing unit can automatically adjust the curing parameters according to different environmental conditions and strength requirements of the T-shaped beam plate. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 A process flow diagram illustrating one illustrative embodiment of the beam plate prefabrication integrated production line in the present application; Figure 2 A connection diagram illustrating one illustrative embodiment of the beam plate prefabrication integrated production line in the present application; Figure 3 A structure diagram illustrating one illustrative embodiment of the beam plate prefabrication integrated production line in the present application; Figure 4 A structure diagram illustrating one illustrative embodiment of the beam plate prefabrication integrated production line in the present application; Figure 3 A partial enlarged view of position A in the present application; Figure 5 A partial enlarged view of position B in the present application; Figure 3 Figure 6 ​Front view of a sectional view of one of the illustrative embodiments of the beam slab prefabrication integrated production line of the present application; Figure 7 Front view of a sectional view of one of the illustrative embodiments of the beam slab prefabrication integrated production line of the present application; Figure 6 Front view of a sectional view of one of the illustrative embodiments of the beam slab prefabrication integrated production line of the present application; Figure 8 Front view of a sectional view of one of the illustrative embodiments of the beam slab prefabrication integrated production line of the present application; Figure 9 Front view of a sectional view of one of the illustrative embodiments of the beam slab prefabrication integrated production line of the present application; Figure 8 Front view of a sectional view of one of the illustrative embodiments of the beam slab prefabrication integrated production line of the present application; Figure 10 Front view of a sectional view of one of the illustrative embodiments of the beam slab prefabrication integrated production line of the present application; Figure 11 Front view of a sectional view of one of the illustrative embodiments of the beam slab prefabrication integrated production line of the present application; Figure 10 Front view of a sectional view of one of the illustrative embodiments of the beam slab prefabrication integrated production line of the present application.

[0024] List of components and reference numerals: 01, ground rail; 02, steel bar processing unit; 03, movable mold table; 04, mold closing mechanism; 05, concrete pouring unit; 06, steam curing unit; 07, finished product transfer unit; 1, movable platform; 11, pouring area; 12, hydraulic jack; 2, strip-shaped mold table; 21, transfer groove; 23, hydraulic support rod; 24, I-shaped bearing plate; 25, step; 26, cushion block; 3, inclined sliding seat; 31, inclined plate; 4, T-shaped mold plate; 41, arc-shaped bottom wall; 42, lifting ring; 5, side mold plate; 51, support frame; 52, sliding plate; 53, cushion plate; 54, anti-falling plate; 55, connecting plate; 551, U-shaped groove; 56, limiting pull rod; 57, limiting groove; 58, limiting plate; 6, support steel wall; 61, hydraulic rod; 7, transfer trolley; 71, steel wheel; 72, lifting hole; 8, demolding vibrator; 9, T-shaped steel bar framework. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the present application.

[0026] It should be noted that the left, right, up, down, front, back and other orientation terms in the embodiments of the present application are only relative concepts or are referenced to the normal use state of the product, i.e., the running direction of the product, and should not be considered as limiting.

[0027] In addition, it should be noted that the "relative motion" and other dynamic terms mentioned in the embodiments of the present application not only include position changes, but also include movements that do not change the position but change the state.

[0028] Finally, it should be noted that when a component is referred to as "located" or "disposed" on another component, it can be on the other component or can have a centering component. When a component is referred to as "connected to" another component, it can be directly connected to the other component or can have a centering component.

[0029] In the prior art, the T-beam slab prefabrication process has vertical and horizontal double contact surfaces between the mold and the concrete member. The traditional demolding method causes friction damage when the mold is separated. This friction not only causes scratches on the surface of the concrete, but also can damage the internal structure, and requires high-power equipment to drive, resulting in high energy consumption and low efficiency.

[0030] To solve the above problems, the present application changes the separation path of the mold and the member (T-beam slab) to reduce the contact area between the mold and the member (T-beam slab) during separation. By analyzing the friction mechanics model, a solution of changing the motion trajectory of the mold is proposed. Based on the modular production concept, an integrated production line layout is designed to connect the mold motion mechanism and the concrete curing process, forming a continuous operation process.

[0031] Therefore, the present application proposes a beam slab prefabrication integrated production line as shown in Figures 1 to 11 The beam slab prefabrication integrated production line includes a steel bar processing unit 02, a movable mold table 03, a mold closing mechanism 04, a concrete pouring unit 05, a steam curing unit 06, and a finished product transfer unit 07 arranged in sequence along the extension direction of the ground rail 01. The steel bar processing unit 02 processes to form a T-shaped steel reinforcement skeleton 9. The movable mold table 03 includes a movable platform 1, a strip-shaped mold table 2 with a transfer groove 21, inclined sliding seats 3 on both sides of the strip-shaped mold table 2, two oppositely arranged T-shaped mold plates 4, and two oppositely arranged side mold plates 5. The mold closing mechanism 04 is connected to the support frame 51 of the side mold plate 5 through the support steel wall 6 and the hydraulic rod 61 to realize mold closing and demolding. The finished product transfer unit 07 is configured with a hydraulic support rod 23, a work-shaped bearing plate 24, a transfer trolley 7, and a gantry crane.

[0032] The inclined sliding seat 3 is a guide device with a height decreasing feature, which can be implemented by welding an inclined rail with a U-shaped steel component. The height change causes the side mold plate 5 to produce an inclined displacement trajectory. The strip-shaped mold table 2 is a base platform for bearing pouring operations, which can be implemented by welding a box-shaped structure with a steel plate. The transfer groove 21 opened in the inside allows the transfer of the finished product member T-beam slab. The hydraulic support rod 23 is an executive element with lifting function, which can be implemented by a multi-stage hydraulic cylinder. The lifting action of the bearing plate is driven by oil pressure.

[0033] Specifically, the skeleton prepared by the rebar processing unit 02 is positioned on the surface of the strip formwork 2, T-shaped templates 4 are installed, and the side templates 5 move along the inclined slides 3 to form a closed pouring space. After the concrete hardens, the hydraulic rod 61 drives the support frame 51 to move outward along the inclined slides 3, creating an inclined separation path between the side templates 5 and the T-shaped beam. The hydraulic struts 23 at the bottom of the T-shaped beam descend, replacing the I-shaped bearing plate 24 with a transfer cart 7. The gantry crane lifts the transfer cart 7 and then lifts the T-shaped beam to transfer it to the storage area. The entire process reduces the contact friction between the side templates 5 and the T-shaped beam through the inclined separation mechanism.

[0034] Compared to existing technologies, traditional demolding devices can only achieve movement in a single vertical or horizontal direction. This solution uses an inclined slide block 3 to create a composite motion trajectory, causing the separation direction of the side template 5 to form an angle with the surface of the T-beam. In conventional production lines, equipment for each process is dispersed; this solution uses ground rails 01 connected in series to form a streamlined operation. Existing transfer equipment requires additional lifting devices; this solution utilizes the built-in transfer groove 21 on the strip mold table 2 to achieve the translation of the T-beam.

[0035] Through the above technical solutions, this application effectively avoids direct friction between the side formwork 5 and the concrete surface of the T-beam slab during demolding, maintaining the surface integrity of the component. The oblique separation mechanism reduces demolding resistance, decreases equipment energy consumption, and extends component lifespan. The integrated layout shortens process transfer time and improves production line efficiency. The built-in transfer system enables damage-free transfer of finished products, avoiding the risk of structural damage caused by secondary hoisting.

[0036] The process flow of this device is as follows: 1. The steel bar processing unit 02 processes the steel bars to form a T-shaped steel bar skeleton 9, and uses a gantry crane to lift the T-shaped steel bar skeleton 9 to the pouring area 11 above the movable formwork 03.

[0037] 2. Install the pad 26 onto the step 25 of the strip formwork 2 using the limiting bolts. Use a gantry crane to lift the T-shaped template 4 so that the arc-shaped bottom wall 41 of the T-shaped template 4 is inserted into the area between the side wall of the pad 26 and the strip formwork 2, thereby achieving the initial fixation of the T-shaped template 4.

[0038] 3. Hingedly install the hydraulic rod 61 of the mold closing mechanism 04 between the support frame 51 and the supporting steel wall 6. The hydraulic rod 61 extends, and the support frame 51 and the side template 5 move toward the strip mold table 2 until the two side templates 5 squeeze the T-shaped template 4 to form the pouring area 11 (the two side templates 5 squeezing the T-shaped template 4 can clamp and position the T-shaped template 4).

[0039] 4, the limiting plate 58 is inserted into the limiting groove 57 to prevent the position deviation of the T-shaped formwork 4 during pouring; the limiting pull rod 56 is installed between the connecting plates 55 of the two side formworks 5.

[0040] 5, the concrete pouring unit 05 pours concrete in the pouring area 11 to form a T-shaped beam slab.

[0041] 6, the hydraulic rod 61 between the mold closing mechanism 04 and the support frame 51 is removed, and the movable mold table 03 is moved into the steam curing unit 06 for mold curing; 7, the limiting pull rod 56 is removed, and the demolding vibrator 8 is started to separate the two side formworks 5 from the T-shaped beam slab (since the side formworks 5 are slidingly connected with the inclined sliding seat 3, a very small force can be used to move the side formworks 5); if the side formworks 5 cannot be manually or simply instrumentally moved, the movable mold table 03 can also be moved to the mold closing mechanism 04, the hydraulic rod 61 is installed to the support frame 51, and the hydraulic rod 61 is retracted to separate the side formworks 5 from the T-shaped beam slab; 8, the cushion block 26 installed on the step 25 of the strip-shaped mold table 2 is removed, and the row hoist is used to tilt and lift the T-shaped formwork 4 away (it should be noted that since the side of the T-shaped formwork 4 away from the T-shaped beam slab has no limiting structure, when lifting the T-shaped formwork 4, the T-shaped formwork 4 should be tilted and lifted to avoid vertical lifting and causing wear between the T-shaped formwork 4 and the T-shaped beam slab); 9, the movable mold table 03 drives the T-shaped beam slab into the steam curing unit 06 for demolding and curing; 10, the hydraulic support rod 23 at the bottom of the T-shaped beam slab is lowered, the T-shaped beam slab is replaced with the transfer trolley 7, the row hoist lifts the transfer trolley 7 and then lifts the T-shaped beam slab to transfer the T-shaped beam slab to the storage area.

[0042] The application further proposes that the inclined sliding seat 3 is in a U shape and is provided with two groups of inclined plates 31 at the top, the bottom of the support frame 51 is provided with a sliding plate 52 abutting against the inclined plates 31, the width of the sliding plate 52 is greater than the width of the inclined plates 31, the two sides of the sliding plate 52 are further provided with the cushion block 26 and the anti-disengagement plate 54, the thickness of the cushion block 26 is greater than the thickness of the inclined plates 31, the anti-disengagement plate 54 is located on the side of the inclined plate 31 away from the sliding plate 52, and the fastening bolt penetrates and fixes the sliding plate 52, the cushion block 26 and the anti-disengagement plate 54.

[0043] The inclined sliding seat 3 is arranged in a U-shaped manner on the movable mold base 03, and can be formed by bending a steel plate to form a structure with two side plates and an upper and lower plate for supporting the sliding plate 52. The inclined plate 31 is an inclined guide plate, which can be fixed on the top of the U-shaped sliding seat by welding to form two inclined tracks for guiding the sliding plate 52 to slide at a predetermined angle. The width of the sliding plate 52 is greater than the width of the inclined plate 31, that is, the lateral dimension of the sliding plate 52 exceeds the edge of the inclined plate 31, which can be processed by a rectangular steel plate so that the edges of the sliding plate 52 cover the inclined plate 31 to prevent misalignment between the sliding plate 52 and the inclined plate 31. The thickness of the cushion block 26 is greater than the thickness of the inclined plate 31, that is, the vertical dimension of the cushion block 26 exceeds the thickness of the inclined plate 31, which can be processed by a metal block to form a gap between the cushion block 26 and the sliding plate 52, providing a sliding space for the sliding plate 52 to slide relative to the inclined plate 31. The anti-disengagement plate 54 is located outside the inclined plate 31, that is, the plate-shaped structure is arranged on the side of the inclined plate 31 away from the sliding plate 52, which can be fixed by welding an angle steel or a steel plate to block the sliding plate 52 from disengaging from the edge of the inclined plate 31. The fastening bolt penetrates and fixes the sliding plate 52, the cushion block 26 and the anti-disengagement plate 54, that is, the bolt passes through the three and is locked, which can be a high-strength bolt with a nut to form a rigid connection to prevent the sliding plate 52 from shifting during sliding.

[0044] Specifically, the sliding plate 52 is in contact with the surface of the inclined plate 31 through the bottom plane and moves in the inclined direction under the guidance of the inclined sliding seat 3. The design that the width of the sliding plate 52 exceeds the edge of the inclined plate 31 ensures that the sliding plate 52 covers the inclined plate 31 during movement, avoiding local stress concentration due to insufficient contact area. The cushion block 26 is installed on both sides of the sliding plate 52, and its thickness is greater than that of the inclined plate 31, forming a gap between the inclined plate 31 and the anti-disengagement plate 54 to reduce the sliding friction resistance between the inclined plate 31 and the anti-disengagement plate 54. The anti-disengagement plate 54 is fixed with the sliding plate 52 and the cushion block 26 by bolts to form a constraint structure surrounding the edge of the inclined plate 31, preventing the sliding plate 52 from disengaging from the inclined plate 31 under vibration or impact. The fastening bolt rigidly connects the three to ensure that the sliding plate 52 maintains a stable posture during movement.

[0045] Compared with the prior art, the sliding plate 52 in the traditional stripping mechanism often moves in a vertical plane, and it is difficult to strip due to the large adhesion between the T-shaped beam plate and the side mold plate 5. In the present device, the side mold plate 5 has a force to slide downward along the inclined plate 31 under its own gravity, so the power requirement of the stripping equipment is low. The combined design of the cushion block 26 and the anti-disengagement plate 54 forms multiple limit positions, effectively preventing the sliding plate 52 from disengaging or shifting, and improving the stability of the stripping process.

[0046] By the technical scheme, the present application solves the problem that the existing stripping equipment has high stripping power requirement for the side mold plate 5 and stripping is difficult, reduces contact friction through oblique sliding and gap control, avoids the deflection of the sliding plate 52 through the anti-stripping structure, ensures the stability of the separation of the mold and the concrete component during the stripping process, and reduces the equipment wear risk.

[0047] The present application further proposes that the plate head and the plate tail of the sliding plate 52 and the anti-stripping plate 54 are both tilted towards the direction away from the inclined plate 31.

[0048] The sliding plate 52 refers to a plate-shaped component that is in contact with the surface of the inclined plate 31 at the bottom, which can be formed by stamping a steel plate, and the two ends are bent upwards to form a tilted structure, and the tilt angle can be 5-15 degrees, which reduces the sliding resistance by reducing the contact area between the sliding plate 52 and the inclined plate 31. The anti-stripping plate 54 refers to a limiting component installed on both sides of the sliding plate 52, which can be fixed by welding a steel plate, and the end is bent upwards to form a tilted structure, and the tilt height can be 10-20 mm, and the tilted edges are provided on both sides of the sliding plate 52 and the anti-stripping plate 54 to make the sliding plate 52 and the anti-stripping plate 54 more smooth when sliding along the inclined plate 31.

[0049] Specifically, the tilted end of the sliding plate 52 and the anti-stripping plate 54 forms a guide slope during movement, and when the side mold plate 5 moves along the inclined sliding seat 3, the tilted structure can avoid hard collision between the sliding plate 52 and the surface protrusions of the inclined plate 31, and reduce the friction area of the contact surface between the sliding plate 52 and the inclined plate 31. When the sliding plate 52 moves to the end of the inclined plate 31, the tilted end can guide the sliding plate 52 to naturally transition along the slope of the inclined plate 31, preventing hard collision of the sliding plate 52.

[0050] Compared with the prior art, the traditional sliding plate 52 adopts a flat plate structure, which is prone to poor movement due to excessive contact surface friction during oblique sliding, and the end of the sliding plate 52 is prone to collision with the edge of the inclined plate 31, which can produce metal debris to pollute the pouring area 11.

[0051] Through the above technical scheme, the present application solves the problem of jamming of the sliding plate 52 caused by friction resistance during oblique movement, ensures the smooth movement of the side mold plate 5 along the inclined sliding seat 3, avoids the position deviation of the side mold plate 5 caused by the jamming of the sliding plate 52, and improves the forming precision and stripping efficiency of the T-shaped beam plate.

[0052] The present application further proposes that the both ends of the strip-shaped mold table 2 are provided with steps 25, and the steps 25 are provided with pad blocks 26 through limiting bolts, the height of the pad blocks 26 is flush with the top surface of the strip-shaped mold table 2, the distance between the side wall of the pad block 26 and the strip-shaped mold table 2 is equal to the thickness of the T-shaped mold plate 4, the bottom wall of the T-shaped mold plate 4 is arc-shaped and located below the top surface of the strip-shaped mold table 2, and the top of the T-shaped mold plate 4 is provided with a lifting ring 42.

[0053] The step 25 refers to a recess structure arranged at the end of the strip-shaped mold table 2, which can be formed by welding or casting, and is used to provide a mounting reference surface for the pad 26 and fix the pad 26. The limiting bolt refers to a fastener penetrating through the pad 26 and the step 25, which can be implemented by a high-strength bolt, and is used to fix the pad 26 on the step 25 to prevent the pad 26 from moving during pouring. The pad 26 refers to a supporting block mounted on the step 25, which can be made of steel plate or cast iron, and the spacing between the side wall of the pad 26 and the strip-shaped mold table 2 is designed to be equal to the thickness of the T-shaped template 4, which is used to limit and fix the bottom of the T-shaped template 4. The arc-shaped bottom wall 41 refers to a curved transition structure at the bottom of the T-shaped template 4, which can be processed by a numerical control machine. The arc-shaped bottom wall 41 can make the T-shaped template 4 more smoothly enter the limiting area between the pad 26 and the strip-shaped mold table 2, and when demolding, the T-shaped template 4 can be rotated around the center line of the arc-shaped bottom wall 41, avoiding the plane friction between the T-shaped template 4 and the T-shaped beam plate during demolding operation, and reducing the quality of the T-shaped beam plate. The lifting ring 42 refers to a ring-shaped member mounted on the top of the T-shaped template 4, which can be fixed by welding or bolt connection, and is used to vertically lift the T-shaped template 4 by hoisting equipment.

[0054] Specifically, after the steps 25 are arranged at both ends of the strip-shaped mold table 2, the pad 26 is fixed on the step 25 by the limiting bolt, and the top surface of the pad 26 is flush with the top surface of the strip-shaped mold table 2, ensuring that the T-shaped template 4 forms stable contact between the bottom wall and the strip-shaped mold table 2 when installed. When the T-shaped template 4 is placed between the side wall of the pad 26 and the strip-shaped mold table 2, its thickness matches the spacing between the two, achieving accurate positioning. When demolding, the pad 26 is first removed, the arc-shaped bottom wall 41 of the T-shaped template abuts against the side surface of the strip-shaped mold table 2 and does not abut against the T-shaped beam plate, and the T-shaped template 4 is lifted obliquely by the row hoist, that is, the T-shaped template 4 first rotates around the center line of the arc-shaped bottom wall 41 to separate from the T-shaped beam plate, and then is hoisted to the storage area by the row hoist.

[0055] Compared with the prior art, the T-shaped template 4 in the existing production line is usually directly placed on the flat mold table surface, and when demolding, the template and the concrete produce large frictional resistance due to horizontal contact. The present scheme changes the contact surface form by the arc-shaped bottom wall 41 structure, so that the T-shaped template 4 first tilts to separate from the concrete surface of the T-shaped beam plate, and then is lifted and moved away from the movable mold table 03 under the action of the row hoist.

[0056] Through the above technical scheme, the damage problem caused by the friction between the T-shaped template 4 and the concrete surface during demolding is effectively solved. By rotating the arc-shaped bottom wall 41 by a certain angle and combining with the inclined lifting method, the frictionless separation is realized, and the positioning accuracy of the T-shaped template 4 is improved by the cooperation of the pad 26 and the limiting bolt, avoiding secondary friction caused by mispositioning, so as to ensure the appearance quality and structural strength of the T-shaped beam plate.

[0057] The side walls of the two side formwork plates 5 are provided with connecting plates 55 aligned with each other, U-shaped grooves 551 are formed in the connecting plates 55, and limiting pull rods 56 are installed between the two connecting plates 55, the limiting pull rods 56 can prevent the side formwork plates 5 from moving away from the pouring area 11, and a hydraulic jack 12 is also installed on the moving platform 1 and located directly below the support frame 51.

[0058] The connecting plate 55 refers to a plate-shaped structure fixed to the side wall of the side formwork plate 5, which can be achieved by welding or bolt connection, and is used to provide an installation position for the limiting pull rod 56. The U-shaped groove 551 refers to a groove structure formed in the connecting plate 55, which can be formed by machining, and is used to accommodate the limiting pull rod 56 and limit its displacement direction. The limiting pull rod 56 refers to a rigid rod that spans the two connecting plates 55, which can be made of threaded steel or alloy steel, and achieves lateral limiting of the side formwork plate 5 by being inserted into the U-shaped groove 551. The hydraulic jack 12 refers to a hydraulic support device installed on the moving platform 1, which can be achieved by a double-acting hydraulic cylinder structure, and is used to provide a vertical force below the support frame 51.

[0059] Specifically, after the mold is closed, the limiting pull rod 56 is inserted into the U-shaped groove 551 of the two connecting plates 55, the length of the pull rod is adjusted to keep the two side formwork plates 5 at a predetermined distance, and the outward deviation is prevented. When pouring concrete, the side formwork plate 5 may be displaced due to fluid pressure, and the rigid constraint of the limiting pull rod 56 can effectively offset the force. The hydraulic jack 12 is located directly below the support frame 51 and can apply a jacking force during the concrete setting stage to compensate for the sinking deformation of the support frame 51 due to the load, thereby maintaining the geometric accuracy of the formwork system. During the demolding stage, the hydraulic jack 12 can adjust the support height to cooperate with the formwork separation action.

[0060] Compared with the prior art, in the traditional demolding process, the side formwork plate 5 only relies on its own stiffness to resist the side pressure of the concrete, which is prone to deformation displacement and causes friction between the formwork and the beam surface. The present scheme forms a rigid constraint system through the limiting pull rod 56, and cooperates with the dynamic support of the hydraulic jack 12, which not only ensures the positioning accuracy of the side formwork plate 5, but also avoids the stress concentration problem caused by rigid constraint.

[0061] Through the above technical scheme, the displacement of the side formwork plate 5 during the pouring and curing stages is effectively controlled, the contact friction between the formwork and the concrete surface during the demolding process is avoided, surface scratches and internal structure damage are avoided, and at the same time, the adjustable hydraulic support system adapts to the load changes under different working conditions, thereby improving the stability and service life of the formwork system.

[0062] The inner side of the side formwork 5 is provided with a limiting groove 57, and the limiting groove 57 is inserted and connected with a limiting plate 58. The limiting plate 58 is located outside the pouring area 11 and abuts against the T-shaped formwork 4.

[0063] The limiting groove 57 is a groove structure formed on the inner side of the side formwork 5 and can be formed by mechanical milling or casting process. The limiting plate 58 is a metal plate matched with the limiting groove 57 and can be formed by cutting a steel plate. The limiting plate 58 is inserted into the limiting groove 57 to form a mechanical constraint and is used to limit the lateral displacement of the T-shaped formwork 4 during pouring.

[0064] Specifically, during the clamping stage, the limiting plate 58 is inserted into the limiting groove 57 of the side formwork 5, and the end thereof is in surface contact with the side wall of the T-shaped formwork 4. When the concrete is poured, the T-shaped formwork 4 is subjected to lateral pressure of the concrete, and the limiting plate 58 prevents the T-shaped formwork 4 from moving outward by rigid abutment, thereby maintaining the geometric accuracy of the formwork system. During the demolding stage, the insertion structure of the limiting plate 58 and the limiting groove 57 allows the side formwork 5 to be separated in the vertical direction, thereby avoiding the sliding friction between the formwork and the concrete surface during the traditional demolding process.

[0065] Compared with the prior art, the traditional demolding method relies on the direct contact constraint between the formwork and the concrete, and the sliding friction during demolding causes surface damage. The present application provides rigid positioning during the pouring stage and converts into a friction-free vertical separation path during the demolding stage by the insertion constraint of the limiting groove 57 and the limiting plate 58, thereby fundamentally eliminating the relative sliding of the contact surface between the formwork and the concrete.

[0066] Through the above technical scheme, the present application effectively avoids the frictional damage between the T-shaped formwork 4 and the concrete surface of the T-shaped beam plate during the demolding process, ensures the surface integrity and dimensional accuracy of the T-shaped beam plate, reduces the demand for equipment thrust during demolding operation, prolongs the service life of the T-shaped formwork 4 and improves the demolding efficiency.

[0067] The present application further provides that the side formwork 5 is provided with a demolding vibrator 8, and the demolding vibrator 8 can apply vibration to the side formwork 5 to assist the separation of the T-shaped beam plate and the side formwork 5.

[0068] The demolding vibrator 8 is a mechanical vibration device installed on the side formwork 5 and can be implemented by an electric eccentric vibrator or a pneumatic high-frequency vibrator. The vibration energy is transmitted to the contact interface between the concrete and the side formwork 5 through the side formwork 5 to destroy the adhesion therebetween. The vibration application direction is the direction of the exciting force generated by the vibrator and can be perpendicular to the inner wall of the side formwork 5 or form an angle with the demolding direction. The separation speed of the side formwork 5 and the concrete can be controlled by adjusting the vibration frequency and amplitude.

[0069] Specifically, the demolding vibrator 8 is started in the demolding stage, and the vibration energy is transmitted to the concrete contact surface through the side mold plate 5, so that high-frequency micro-amplitude vibration is generated between the concrete surface layer and the side mold plate 5, a micro gap is formed to reduce the frictional resistance of the contact surface. During the vibration process, the adhesion between the side mold plate 5 and the T-beam plate is gradually destroyed, and when the side mold plate 5 moves along the inclined sliding seat 3, only the residual friction needs to be overcome, avoiding the damage to the concrete surface caused by traditional hard pulling. For example, when the hydraulic rod 61 drives the support frame 51 to move outward, the vibrator is started synchronously and continues until the side mold plate 5 is completely separated from the surface of the T-beam plate.

[0070] Compared with the prior art, the traditional demolding operation relies on the hydraulic mechanism to forcibly separate the mold plate from the concrete, and the contact surface friction causes surface scratches and structural damage. The vibration-assisted demolding makes the side mold plate 5 and the concrete controllably separate by reducing the interfacial adhesion, and the contact surface friction is effectively weakened by the vibration energy. The prior art does not use vibration demolding means, and cannot dynamically adjust the interfacial friction state during the mold plate movement.

[0071] Through the above technical scheme, the present application solves the problem of surface damage caused by hard friction between the side mold plate 5 and the concrete during demolding. The vibration energy makes the contact surface between the side mold plate 5 and the T-beam plate controllably separate, reduces the demolding resistance, maintains the integrity of the concrete surface, reduces the power load of the demolding equipment, and prolongs the service life of the hydraulic elements.

[0072] The production line further comprises a central control system, which is in control connection with the reinforcing steel bar processing unit 02, the movable mold table 03, the mold closing mechanism 04, the concrete pouring unit 05, the steam curing unit 06 and the finished product transfer unit 07.

[0073] The central control system is an integrated control platform, which can be realized by a programmable logic controller or an industrial computer, and establishes a data interaction link with each unit through a communication protocol to realize automatic scheduling and real-time monitoring of the production process. The control connection refers to the relationship between signal transmission and instruction execution, which can be realized by a wired or wireless communication module, for example, by using Ethernet, RS485 bus or wireless radio frequency technology to transmit control instructions, so that the central control system can synchronize and coordinate the action timing of each unit.

[0074] Specifically, the central control system controls the skeleton forming parameters of the steel bar processing unit 02, the positioning accuracy of the movable mold table 03, the stroke of the hydraulic rod 61 of the mold closing mechanism 04, the distribution speed of the concrete pouring unit 05, the temperature and humidity curve of the steam curing unit 06, and the transfer path of the finished product transfer unit 07 through a preset program. For example, when the movable mold table 03 enters the mold closing station, the central control system synchronously triggers the extension action of the hydraulic rod 61 to ensure that the side mold plate 5 and the T-shaped mold plate 4 are accurately closed; during the steam curing stage, the system automatically switches the primary mold curing and secondary demolding curing modes according to the preset time to avoid temperature control deviation caused by manual operation.

[0075] Compared with the prior art, the traditional production line relies on manual segmented operation, and the coordination between units is poor, which is prone to process connection delay or parameter matching error. The global scheduling of the central control system eliminates the problem of asynchronous action caused by human intervention, such as automatically coordinating the start and stop of the demolding vibrator 8 and the lifting action of the hydraulic support rod 23 during the demolding stage, to avoid damage to the concrete surface caused by the timing error of the operation.

[0076] Through the above technical solutions, the present application realizes full-automatic closed-loop control of the production process, reduces the damage to the mold friction and the concrete structure caused by human operation errors, and improves the coordination efficiency of each unit to ensure the consistency of the T-shaped beam plate forming quality and the production rhythm.

[0077] The present application further proposes that the concrete pouring unit 05 comprises a torpedo tank and a distributor; and the steam curing unit 06 can perform primary mold curing and secondary demolding curing on the T-shaped beam plate.

[0078] The torpedo tank refers to a sealed container for transporting ready-mixed concrete, which can be implemented by a metal tank body with a rotating discharge port, and its sealing structure can prevent concrete segregation. The distributor refers to a device for uniformly spreading concrete to the mold, which can be implemented by a movable mechanical arm with a screw conveyor to realize continuous filling of the pouring area 11 through reciprocating motion. The primary mold curing refers to steam curing under the condition that the mold is closed after the concrete has initially set, and the temperature and humidity are maintained in the closed space; the secondary demolding curing refers to supplementary curing on the surface of the exposed T-shaped beam plate after the side mold plate 5 and the T-shaped mold plate 4 are removed, which can be implemented by a segmented steam nozzle covering the beam surface.

[0079] Specifically, the torpedo tank is transported to above the distributing machine through the track, the concrete is dropped into the receiving hopper of the distributing machine through the rotating discharge port, and the spiral conveyor uniformly spreads the concrete along the length direction of the strip-shaped mold table 2. In the initial mold maintaining stage, steam is input into the closed pouring area 11 through the pipe at the bottom of the mold table, so that the concrete completes the preliminary strength growth in the constant temperature and humidity environment; in the secondary demolding maintaining stage, steam is sprayed from the adjustable nozzles at the top and side of the T-shaped beam plate, and the exposed surface after demolding is subjected to directional humidification.

[0080] In some specific embodiments, the capacity of the torpedo tank can be 8-12 cubic meters, the conveying speed of the distributing machine can be adjusted to 0.5-1.2 meters per minute. The temperature control range of the steam curing unit 06 can be set to 40-60℃, the initial curing duration can be 6-8 hours, and the secondary curing duration can be 4-6 hours.

[0081] Through the above technical solution, the present application effectively avoids the adhesion damage of the concrete surface of the T-shaped beam plate to the side mold plate 5 and the T-shaped mold plate 4 in the demolding process, ensures the corner integrity and surface flatness of the T-shaped beam plate, and reduces the generation of internal stress cracks of the concrete through staged temperature control, so that the curing energy consumption is reduced by about 20%-30%. The continuous paving operation of the distributing machine makes the pouring efficiency 3-5 times higher than that of the traditional manual operation, and the sealing design of the torpedo tank controls the concrete slump loss rate within 2%.

[0082] The present application further proposes that the transfer trolley 7 can move to the transfer groove 21, the bottom of the transfer trolley 7 is provided with a steel wheel 71, the length of the transfer trolley 7 is greater than the width of the part of the T-shaped beam plate abutting to the transfer trolley 7, and the part of the transfer trolley 7 protruding from the T-shaped beam plate is provided with a lifting hole 72.

[0083] The transfer trolley 7 is a mobile device for carrying and transporting the formed T-shaped beam plate, which can be specifically realized by a flat trolley with a steel frame and a roller, and the bottom steel wheel 71 is movable. The steel wheel 71 is a metal roller installed at the bottom of the transfer trolley 7, which can be specifically realized by a forged steel wheel 71 with a bearing, capable of bearing heavy load and reducing rolling resistance. The lifting hole 72 is a circular through hole formed in the protruding part of the transfer trolley 7, which can be specifically formed by drilling or stamping process, so as to facilitate the lifting hook of the hoisting equipment to pass through and be fixed.

[0084] Specifically, when the hydraulic support rod 23 jacks up the I-shaped bearing plate 24 to be flush with the strip-shaped mold base 2, concrete is poured into the pouring area 11. After the concrete of the T-shaped beam slab is completed and the secondary curing is formed, the hydraulic support rod 23 is lowered, the I-shaped bearing plate 24 is removed, and the transfer trolley 7 is moved into the transfer groove 21. The length is designed to ensure that the T-shaped beam slab has protruding areas on both sides when placed. The lifting hole 72 is positioned away from the main body of the T-shaped beam slab. After the transfer trolley 7 enters the range of the lifting device, the lifting device directly lifts the transfer trolley 7 and the T-shaped beam slab through the lifting hole 72 without additional adjustment of the lifting device position.

[0085] Compared with the prior art, the conventional transfer trolley 7 has the same width as the beam slab, and the lifting device needs to be temporarily installed on both sides of the beam slab during lifting, which is easy to cause damage to the concrete surface. The present application lengthens the transfer trolley 7 and pre-installs the lifting hole 72 in the protruding part, so that the lifting force directly acts on the frame of the transfer trolley 7, avoiding stress on the beam slab body, while reducing the lifting preparation time.

[0086] Through the above technical scheme, the present application effectively prevents the concrete surface damage caused by contact or extrusion during lifting, improves the finished product transfer efficiency, and reduces the influence of lifting operation on the structural integrity of the beam slab.

[0087] In an embodiment, in the mountainous highway bridge construction project, due to the complex terrain conditions, the transportation and installation of the T-shaped beam slab bring certain difficulties, so higher requirements are put forward for the prefabrication quality and production efficiency of the T-shaped beam slab. The beam slab prefabrication integrated production line of the present application plays an important role in this project.

[0088] For T-shaped beam slabs with different spans and bearing requirements in the project, the technical personnel finely adjust the specifications and processing technology of the steel bars in the steel bar processing unit 02. For T-shaped beam slabs with large span and high bearing requirement, the diameter and number of steel bars are increased, and the welding process is optimized to ensure that the T-shaped steel bar framework 9 has sufficient strength and stability. In the moving mold base 03 part, the corresponding specifications of the T-shaped beam slab and the side mold plate 5 are replaced according to the size of the T-shaped beam slab, and the size of the pouring area 11 is accurately adjusted by adjusting the limiting bolts and pads 26 on the steps 25 at both ends of the strip-shaped mold base 2 and the limiting plate 58 inside the side mold plate 5, to ensure the forming accuracy of the T-shaped beam slab.

[0089] During the concrete pouring process, considering the mountainous construction environment and the characteristics of the concrete raw materials, the operating parameters of the torpedo tank and the distributing machine of the concrete pouring unit 05 are optimized. The mix proportion of the concrete is adjusted to improve the workability and fluidity of the concrete; at the same time, according to the requirements of the pouring speed and volume, the transportation frequency of the torpedo tank and the distributing speed of the distributing machine are reasonably arranged to ensure that the concrete is continuously and uniformly poured into the pouring area 11, avoiding problems such as pouring interruption and concrete segregation.

[0090] Steam curing unit 06 employs an intelligent temperature control system to monitor the temperature and humidity of the curing area in real time, based on temperature changes in the T-beams in the mountainous environment. It automatically adjusts the steam supply and curing time according to the strength growth data of the T-beams. This minimizes the curing cycle and improves production efficiency while ensuring the quality of the T-beams. During demolding, the synergistic action of the demolding vibrator 8 and hydraulic jacks 12 ensures a smooth demolding process, resulting in smooth, undamaged surfaces for the T-beams after demolding. Finished product transfer unit 07, through a rationally planned route and hoisting sequence, quickly transfers the T-beams to the storage area, saving time for subsequent transportation and installation. Through the efficient operation of this production line, the project completed the T-beam prefabrication task with high quality in a short period, meeting the schedule requirements of the mountainous highway bridge construction.

[0091] The above description is merely an embodiment of this application and is not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. An integrated precast beam and slab production line, characterized in that, It includes a steel bar processing unit, a moving formwork, a formwork closing mechanism, a concrete pouring unit, a steam curing unit, and a finished product transfer unit, arranged sequentially along the direction of the ground rail extension; The steel bar processing unit processes the steel bars to form a T-shaped steel bar skeleton; The movable formwork includes a movable platform, a strip formwork fixed to the center of the movable platform, inclined slides on both sides of the strip formwork, two T-shaped templates and two side templates arranged opposite each other. A transfer groove is provided in the strip formwork. The strip formwork, the T-shaped templates and the side templates together form a casting area that accommodates the T-shaped steel reinforcement skeleton. The side templates are slidably connected to the inclined slides through a support frame and can move along the extension direction of the inclined slides. From the center of the movable platform to its two sides, the height of the inclined slides gradually decreases. The mold closing mechanism is fixed to both sides of the ground rail and is symmetrically arranged relative to the ground rail. The mold closing mechanism includes a supporting steel wall and a hydraulic rod hinged between the supporting steel wall and the support frame. The finished product transfer unit includes a hydraulic strut installed in the transfer trough, an I-shaped support plate fixed to the top of the hydraulic strut, a transfer car and a gantry crane. When the hydraulic strut is in the extended state, the surface of the support plate is flush with the surface of the strip mold table.

2. The integrated precast beam and slab production line according to claim 1, characterized in that, The inclined slide is U-shaped and has two sets of inclined plates at the top. The bottom of the support frame has a slide plate that abuts against the inclined plates. The width of the slide plate is greater than the width of the inclined plates. The sides of the slide plate are also equipped with pads and anti-detachment plates. The thickness of the pads is greater than the thickness of the inclined plates. The anti-detachment plate is located on the side of the inclined plates away from the slide plate. Fastening bolts pass through and fix the slide plate, the pads, and the anti-detachment plate.

3. The integrated precast beam and slab production line according to claim 2, characterized in that, The front and rear ends of both the skateboard and the anti-detachment plate are tilted away from the ramp.

4. The integrated precast beam and slab production line according to claim 1, characterized in that, The strip-shaped mold platform has steps at both ends, and a pad is installed on the steps by limiting bolts. The height of the pad is flush with the top surface of the strip-shaped mold platform. The distance between the side wall of the pad and the strip-shaped mold platform is equal to the thickness of the T-shaped template. The bottom of the T-shaped template has an arc-shaped bottom wall, and the arc-shaped bottom wall is located below the top surface of the strip-shaped mold platform. The top of the T-shaped template is provided with a lifting ring.

5. The integrated precast beam and slab production line according to claim 1, characterized in that, Both side templates have aligned connecting plates on their side walls. The connecting plates have U-shaped grooves. A limit rod is installed between the two connecting plates to prevent the side templates from moving away from the pouring area. A hydraulic jack is also installed on the moving platform, and the hydraulic jack is located directly below the support frame.

6. The integrated precast beam and slab production line according to claim 1, characterized in that, A limiting groove is also provided on the inner side of the side template, and a limiting plate is inserted and installed in the limiting groove. The limiting plate is located on the outer side of the pouring area and abuts against the T-shaped template.

7. The integrated precast beam and slab production line according to claim 1, characterized in that, A demolding vibrator is also installed on the side formwork, which can apply vibration to the side formwork to assist in the separation of the T-beam plate from the side formwork.

8. The integrated precast beam and slab production line according to claim 1, characterized in that, The production line also includes a central control system, which is connected to the steel bar processing unit, the moving mold table, the mold closing mechanism, the concrete pouring unit, the steam curing unit, and the finished product transfer unit.

9. The integrated precast beam and slab production line according to claim 1, characterized in that, The concrete pouring unit includes a torpedo-shaped container and a concrete placing boom; the steam curing unit is capable of performing initial curing with the T-shaped beams formed in the pouring area and secondary curing with the T-shaped beams after demolding.

10. The integrated precast beam and slab production line according to claim 9, characterized in that, The transfer vehicle can move to the transfer trough. The bottom of the transfer vehicle is equipped with steel wheels. The length of the transfer vehicle is greater than the width of the part of the T-shaped beam that abuts against the transfer vehicle. The part of the transfer vehicle that protrudes from the T-shaped beam is provided with lifting holes.

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