Bridge cable hot casting anchor anchoring material and casting device and casting method thereof

Abstract

The invention discloses a bridge cable hot casting anchor anchoring material and a casting device and method thereof, and relates to an anchoring material and a casting device and method thereof, and the anchoring material comprises the following chemical components in percentage by mass: 1.8-2.2% of Cu, 0.2-0.5% of Ti, 0.01-0.05% of Mg, and the balance of Zn and inevitable impurities. The casting device comprises a vertical positioning device; the vertical positioning device comprises an anchor cup connecting assembly and a cable body clamp, a cable pulling hole is formed in the middle of the anchor cup connecting assembly, and the anchor cup connecting assembly is connected with the small end of the taper hole of the anchor cup; the cable body clamp is clamped outside the inhaul cable body, and the top end of the cable body clamp is vertically connected to the bottom end of the anchor cup connecting assembly. The method comprises the following steps: S1, preparing an anchoring material melt; s2, stripping a PE layer of the cable body; s3, positioning a cable body steel wire; s4, mounting a vertical positioning device; s5, preheating is carried out; s6, anchoring material casting and the like. According to the anchoring material, the mechanical properties such as hardness and strength are improved, meanwhile, the creep resistance is improved, and the anchoring performance and the anchoring efficiency of the anchoring material are remarkably improved.

Description

Technical Field

[0001] This invention relates to hot-cast anchor materials and their casting apparatus and methods, particularly a hot-cast anchor material for bridge cables and its casting apparatus and method. Background Technology

[0002] Currently, bridge cables are mainly anchored within anchor cups using either hot-cast or cold-cast anchors. Hot-cast anchors involve spreading the ends of the steel wire within the anchor cup and then casting a zinc-copper alloy for anchoring. When the cable is under tension, the hot-cast anchor relies on the bond between the zinc-copper alloy and the steel wire, as well as the wedging effect of the zinc-copper alloy cone embedded in the anchor cup, to achieve anchoring. The gripping force between the zinc-copper alloy and the steel wire, and the wedging force between the zinc-copper alloy and the anchor cup, are key factors affecting the anchoring performance of hot-cast anchors. Currently, the hot-cast zinc-copper alloy in hot-cast anchors has a composition of 98% zinc and 2% copper by mass, resulting in relatively low anchoring performance. When the strength of the steel wire increases, the existing anchor structure suffers from insufficient gripping force and excessive alloy compressive stress. Insufficient gripping force easily leads to wire pull-out, while excessive alloy compressive stress easily leads to excessive shrinkage, and in severe cases, the entire anchor body may fail. Furthermore, during the casting process, the lack of an effective positioning device leads to eccentricity and non-perpendicularity between the cable body and the anchor cup, resulting in uneven stress on the cable wires within the anchor cup and affecting the cable's anchoring performance. Additionally, as the anchoring material flows from the large end to the small end of the conical hole in the anchor cup, temperature and velocity differences exist between the front and rear ends, causing the anchoring material to have a high porosity and insufficient density, thus affecting anchoring efficiency.

[0003] Patent application CN117845100A discloses a zinc-based multi-element alloy material and casting method for bridge cable anchoring. This zinc-based multi-element alloy material uses Zn, Al, Cu, Mg, and Ti / RE as its components. The addition of Al is intended to refine the grain size, improve the fluidity of the anchoring material, and enhance the alloy's strength and hardness. However, when the Al content is in the range of 5%-30%, as the Al content increases, the solidification temperature range of the alloy increases, but the fluidity gradually decreases. This leads to a higher porosity in the anchoring material, resulting in insufficient density of the castable and a risk of low anchoring efficiency. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a hot-cast anchoring material for bridge cables, as well as its casting device and casting method, to solve the problems of low anchoring performance and low anchoring efficiency in the prior art.

[0005] The technical solution to the above technical problem is: a hot-cast anchor material for bridge cables, the chemical composition of which by mass percentage includes: Cu: 1.8% to 2.2%, Ti: 0.2% to 0.5%, Mg: 0.01% to 0.05%, with the remainder being Zn and unavoidable impurities; wherein the unavoidable impurities are Fe≤0.01% and Pb≤0.003%.

[0006] Another technical solution of the present invention is: a casting device for hot-cast anchorage material for bridge cables, comprising a vertical positioning device; the vertical positioning device comprises an anchor cup connecting assembly and a cable clamp, wherein the anchor cup connecting assembly is a two-half structure, the middle part of the anchor cup connecting assembly is provided with a cable hole I that mates with the cable body, and the anchor cup connecting assembly is connected to the small end of the conical hole of the anchor cup; the cable clamp is a two-half structure, the cable clamp is clamped on the cable body, and the top end of the cable clamp is vertically connected to the bottom end of the anchor cup connecting assembly.

[0007] A further technical solution of the present invention is that the anchor cup connecting assembly has a cross-shaped structure. The anchor cup connecting assembly is composed of two symmetrically arranged anchor cup connecting units connected by bolt pair I. Each anchor cup connecting unit includes an upper support plate and an ear plate. The upper support plate is arranged along the X-axis direction, and one end of the upper support plate is provided with a connecting hole for connecting with the small end of the anchor cup conical hole. The ear plate is fixedly connected to the other end of the upper support plate along the Y-axis direction, and the ear plate is provided with a bolt hole for installing the bolt pair I. The two symmetrically arranged anchor cup connecting units each have half of the cable hole I in the middle of their interconnected end faces.

[0008] A further technical solution of the present invention is that the cable clamp includes two symmetrical crescent-shaped columns, the top of which is vertically connected to the bottom of the anchor cup connecting assembly along the Z-axis. The crescent-shaped column is provided with a continuous inner cavity that mates with the cable body. Two or more rectangular ear plates are fixedly connected to the crescent-shaped column along its axial direction. The two symmetrical crescent-shaped columns are connected together by the rectangular ear plates and bolt II to form a cylindrical sleeve with a cable hole II that mates with the cable body.

[0009] A further technical solution of the present invention is that the casting device is also equipped with a temperature control device on the outside of the anchor cup. The temperature control device includes at least one dynamic heat preservation device, and each dynamic heat preservation device cooperates with the anchor cup to form a closed space.

[0010] A further technical solution of the present invention is that the dynamic heat preservation device has three parts, namely a first-stage dynamic heat preservation device, a second-stage dynamic heat preservation device and a third-stage dynamic heat preservation device. The first-stage dynamic heat preservation device is installed on the outer wall of the small end of the cone hole of the anchor cup, the second-stage dynamic heat preservation device is installed on the outer wall of the middle part of the anchor cup, and the third-stage dynamic heat preservation device is installed on the outer wall of the large end of the cone hole of the anchor cup.

[0011] A further technical solution of the present invention is that the dynamic heat preservation device includes a cylindrical tube, a heating device, and a heat-conducting plate. The upper and lower ends of the cylindrical tube are provided with holes that cooperate with the anchor cup, and the cylindrical tube and the anchor cup form the closed space. The heat-conducting plate is fixedly connected to the inner wall of the cylindrical tube and is arranged in a spiral, inclined, or stepped manner along the outer wall of the anchor cup. The heating device is directly installed on the anchor cup. Each dynamic heat preservation device is also provided with two or more temperature sensors A, which are installed on the heat-conducting plate.

[0012] A further technical solution of the present invention is that the dynamic heat preservation device includes a sleeve, a temperature sensor B, and a heat insulation layer. The inner wall of the sleeve is tightly fitted to the outer surface of the anchor cup, and the inner cavity of the sleeve forms the closed space. The inner cavity is encapsulated with a phase change material, which is a graphene-reinforced composite paraffin phase change material. The sleeve is provided with a filling port and a pressure relief port that connect to its inner cavity. A heating resistance wire is wound and installed on the outer surface of the sleeve. The temperature sensor B is installed on the inner wall of the sleeve. The heat insulation layer is sleeved on the outside of the sleeve, and a cooling channel is provided between the heat insulation layer and the sleeve. The cooling channel is connected to the air inlet and the air outlet respectively.

[0013] Another technical solution of the present invention is a casting method for hot-cast anchorage material for bridge cables, comprising the following steps: S1. Prepare the anchoring material molten liquid; S2. Remove the PE layer of the cable: Remove the PE layer of the steel wires from the anchor sections at both ends of the cable; S3. Positioning of steel wires in the anchor cup: After the PE layer has been removed, the steel wires are sequentially inserted into the inner cavity of the anchor cup and the wire splitting plate. Each steel wire is inserted into the wire splitting plate for dispersion and positioning. Some steel wires are then truncated, and the wire splitting plate is installed on the inner cavity of the large end of the cone hole of the anchor cup. S4. Install the vertical positioning device: After installing the vertical positioning device, connect the upper support plate to the anchor cup, tighten bolt width I and bolt width II on the vertical positioning device, fix the steel wire cable, and ensure that the cable and the anchor cup are always in a vertical state. S5. Preheating: The temperature control device is fitted onto the outside of the anchor cup, and the anchor cup and the cable body inside the anchor cup are preheated by the heating device of the dynamic heat preservation device. The preheating temperature of the anchor cup is 250-350℃; at the same time, the anchoring material is heated to a temperature of 430-460℃. S6. Casting of Anchoring Material: After the anchor cup temperature and the anchoring material temperature reach the required levels, pour the high-temperature anchoring material from the large end of the cone hole of the anchor cup into the inner cone cavity containing the wire rope body; at the same time, turn on the heating device of the first-stage dynamic heat preservation device, observe the temperature sensor, and after the set temperature is reached, turn off the heating device of the first-stage dynamic heat preservation device. After casting is completed, cool it by natural cooling; then, in the same steps, turn on and off the heating devices of the second and third-stage dynamic heat preservation devices in sequence until the hot-cast anchoring material is completely solidified; S7. Perform a top pressure test or an over-tension test on the anchor cup.

[0014] Another technical solution of the present invention is a casting method for hot-cast anchorage material for bridge cables, comprising the following steps: S1. Prepare the anchoring material molten liquid; S2. Remove the PE layer of the cable: Remove the PE layer of the steel wires from the anchor sections at both ends of the cable; S3. Positioning of steel wires in the anchor cup: After the PE layer has been removed, the steel wires are sequentially inserted into the inner cavity of the anchor cup and the wire splitting plate. Each steel wire is inserted into the wire splitting plate for dispersion and positioning. Some steel wires are then truncated, and the wire splitting plate is installed on the inner cavity of the large end of the cone hole of the anchor cup. S4. Install the vertical positioning device: After installing the vertical positioning device, connect the upper support plate to the anchor cup, tighten bolt width I and bolt width II on the vertical positioning device, fix the steel wire cable, and ensure that the cable and the anchor cup are always in a vertical state. S5. Preheating: Heat the anchoring material at a temperature of 430–460℃; S6. Casting of Anchoring Material: Once the anchoring material reaches the required temperature, the heated anchoring material is poured from the large end of the conical hole in the anchor cup into the inner conical cavity containing the wire rope body. Simultaneously, the first-stage dynamic heat preservation device is activated, and the phase change material begins to absorb heat from the anchoring material, slowing down the cooling rate of the anchoring material. As the anchoring material continues to cool, the temperature of the phase change material begins to rise after completing the phase change. If the temperature sensor detects that the temperature exceeds the preset upper limit, the fan is activated to dissipate the excess heat of the phase change material into the environment, causing its temperature to drop. Conversely, if the anchoring material cools too quickly and the temperature of the phase change material falls below the set lower limit, resistance wire heating is activated to maintain the temperature of the phase change material, ensuring that the cooling process of the anchoring material proceeds smoothly until solidification, and the first-stage dynamic heat preservation device is closed. The same steps are then repeated to activate the second and third-stage dynamic heat preservation devices sequentially until all the hot-cast anchoring material has solidified. S7. Perform a top pressure test or an over-tension test on the anchor cup.

[0015] Due to the above structure, the hot-cast anchorage material for bridge cables of the present invention, as well as its casting device and casting method, have the following advantages compared with the prior art: 1. Can improve the anchoring performance of anchoring materials. The chemical composition of the anchoring material of the present invention, by mass percentage, includes: Cu: 1.8% to 2.2%, Ti: 0.2% to 0.5%, Mg: 0.01% to 0.05%, with the remainder being Zn and unavoidable impurities; wherein the unavoidable impurities are Fe≤0.01% and Pb≤0.003%.

[0016] Among the above chemical components: Low-content (≤0.5% by mass) Cu: Adding a small amount of copper to aluminum alloys can enhance their resistance to atmospheric corrosion and improve their strength through solid solution strengthening; Medium-content (1%-10% by mass) Cu: Can improve strength, wear resistance, and machinability; High-content (≥10% by mass) Cu: Used in aerospace structural components. The anchoring material of this invention controls the Cu content at 1.8% to 2.2%, which is a medium content, and can improve the strength, creep resistance, wear resistance, and machinability of the anchoring material.

[0017] A small amount of titanium (Ti) can refine the grain size of aluminum alloys, improve plasticity, reduce heat transfer tendency, and improve surface finish. A moderate Ti content refines the grain size, thus increasing the material's yield strength and fatigue life. However, a higher titanium content can reduce the material's toughness (requiring strict control of the cooling rate). This invention controls the Ti content between 0.2% and 0.5%, which is considered a moderate content. This refines the grain size, accelerates the flowability of the anchoring material, and not only improves the material's hardness and strength but also enhances its creep resistance, yield strength, and fatigue life.

[0018] A small amount of magnesium (Mg) improves strength while maintaining good toughness. Because Mg lowers the stacking fault energy of aluminum, it improves cold rolling and stamping properties; moderate Mg significantly improves strength, and Mg vapor can suppress weld porosity, improving weldability. However, a content greater than 6% leads to weld embrittlement. This invention controls the Mg content to 0.01–0.05%, achieving good toughness while improving strength.

[0019] The present invention also controls unavoidable impurities to a low range: Fe≤0.01%, Pb≤0.003%, which can effectively reduce brittle phases.

[0020] Therefore, the anchoring material of the present invention, by adding appropriate amounts of Ti, Cu, and Mg elements to the Zn-Cu alloy, can refine the grains of the Zn-Cu alloy and accelerate the fluidity of the anchoring material. This not only improves the mechanical properties of the Zn-Cu alloy, such as hardness and strength, but also enhances its creep resistance, which is beneficial to improving the fatigue performance of the zinc-copper multi-element alloy. Without increasing the structural size of the anchor, the anchoring performance of the anchoring material is significantly improved.

[0021] In addition, the vertical positioning device in the casting apparatus of the present invention includes an anchor cup connecting assembly and a cable clamp. The anchor cup connecting assembly and the cable clamp are arranged vertically. This arrangement enables vertical positioning between the cable and the anchor cup, effectively solving the problems of eccentricity and bending stress between the cable and the anchor cup, ensuring that the steel wire is subjected to uniform force in the anchor cup, further improving the anchoring performance of the hot-cast anchor, and thus improving the anchoring performance and safety margin of the cable.

[0022] Furthermore, in the casting method of the present invention, the assembled vertical positioning device, cable body, and anchor cup are preheated at a temperature of 250-350°C; at the same time, the anchoring material is heated at a temperature of 430-460°C, which can improve the fluidity of the anchoring material and thus improve its anchoring performance.

[0023] 2. High anchoring efficiency Although the casting material of this invention does not contain Al, by increasing the Ti content, the grain size of the Zn-Cu alloy can be refined, thereby accelerating the flowability of the anchoring material.

[0024] Furthermore, the dynamic heat preservation device in the casting apparatus of this invention has a heat-conducting plate inside that guides heat to be transferred evenly along the axial and radial directions, avoiding localized rapid cooling. This solves the problem of temperature difference between the front and rear ends of the anchor cup causing a difference in the flow rate of the anchoring material, and effectively reduces casting defects such as shrinkage cavities and porosity in the anchoring material within the anchor cup. From a process perspective, it further solves the problem of insufficient density caused by high porosity of the anchoring material and uneven casting, thereby improving anchoring efficiency.

[0025] Furthermore, in the casting method of the present invention, the assembled vertical positioning device, cable body, and anchor cup are preheated at a temperature of 250-350°C; at the same time, the anchoring material is heated at a temperature of 430-460°C, which can improve fluidity, effectively solve the problem of insufficient density, and further improve anchoring efficiency.

[0026] 3. This invention uses phase change materials to replace the traditional air-cooling method, and has the following characteristics: Phase change materials (PCMs) are a class of materials that undergo phase transformation within a specific temperature range and absorb or release a large amount of latent heat. This application applies PCMs to the temperature control system of hot-cast anchorage for bridge cables. By utilizing their phase change properties to precisely control temperature changes during the casting process and guide the anchorage material to solidify sequentially, the quality of the anchorage material can be significantly improved, thereby enhancing the performance and reliability of hot-cast anchorages for bridge cables.

[0027] The technical features of the hot-cast anchorage material for bridge cables of the present invention, as well as its casting device and casting method, will be further described below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0028] Figure 1 Example 4: A schematic diagram of the casting device for the hot-cast anchorage material of the bridge cable of the present invention; Figure 2 : A schematic diagram of the vertical positioning device described in Embodiment 4. Figure 3 Example 4: A schematic diagram of the anchor cup connection assembly. Figure 4 : Front view of the temperature control device described in Embodiment 4 Figure 5 : Figure 4 Top view, Figure 6 Example 5: A schematic diagram of the casting device for the hot-cast anchorage material of the bridge cable of the present invention; Figure 7 : A schematic diagram of the temperature control device described in Example 5; Figure 8 Example 6: Schematic diagram of the temperature control device structure of the casting device for the hot-cast anchorage material of bridge cable according to the present invention; Figure 9 Example 6: A schematic diagram of the temperature control device installed on the anchor cup; In the above figures, the reference numerals are explained as follows: 1-Vertical positioning device, 11-Anchor cup connection assembly, 111-Upper bearing plate, 112-Ear plate, 113-Bolt pair I, 114-Screw, 12-Cable clamp, 121-Crescent post, 122-Rectangular lug, 123-Bolt width II, 2-Temperature control device, 21-Dynamic heat preservation device, 21a - First-stage dynamic insulation device, 21b - Second-stage dynamic insulation device, 21c - Third-stage dynamic insulation device. 211-Columnar cylinder, 2111-Packing inlet, 2112-Pressure relief port, 2113-Buffer chamber, 212-Heating device. 213 - Heat-conducting plate, 214 - Temperature sensor, 215 - Inner sleeve 215 - Sleeve, 2151 - Packing port, 2152 - Pressure relief port, 2153 - Air inlet, 2154 - Air outlet 216 - Temperature sensor B, 217 - Thermal insulation layer, 218 - Heating resistance wire 3-Anchor cup, 4-Cable body, 5-Anchoring material, 6-Phase change material, Q-Air cooling channel. Detailed Implementation Example 1

[0029] A hot-cast anchoring material for bridge cables, the chemical composition of which by mass percentage includes Cu: 1.8%, Ti: 0.5%, Mg: 0.01%, with the remainder being Zn and unavoidable impurities; among the unavoidable impurities, the composition by mass percentage is Fe≤0.01% and Pb≤0.003%. Example 2

[0030] A hot-cast anchoring material for bridge cables, comprising, by mass percentage: Cu: 2.0%, Ti: 0.3%, Mg: 0.03%, with the remainder being Zn and unavoidable impurities. Of the unavoidable impurities, by mass percentage, Fe ≤ 0.01% and Pb ≤ 0.003%. Example 3

[0031] A hot-cast anchoring material for bridge cables, comprising, by mass percentage: Cu: 2.2%, Ti: 0.2%, Mg: 0.05%, with the remainder being Zn and unavoidable impurities. Of the unavoidable impurities, by mass percentage, Fe ≤ 0.01% and Pb ≤ 0.003%.

[0032] To assess the bond strength between the steel wire and the anchoring material, tests were conducted using the hot-cast anchoring materials for bridge cables described in Examples 1 to 3 to verify their bond strength. The tests employed anchor cups of different lengths, with steel wires having a diameter of φ5.6mm and a strength grade of 1960MPa. The bond lengths were 50mm, 100mm, 150mm, and 200mm, respectively. Twenty samples were used for each type of test. The bond strength of the alloy was determined using the formula:

[0033] In the formula: σB is the bond strength between the steel wire and the alloy anchoring material, in MPa; F is the adhesion force between the steel wire and the alloy anchoring material, in N; d is the diameter of the steel wire, in mm; L is the bond length of the steel wire, in mm; Its grip strength is shown in the table below.

[0034] Table 1 – Overview of Bond Strength of Hot-Cast Anchorage Material for Bridge Cables

[0035] Table 1 shows that when the grip length is less than or equal to 100 mm, the failure mode of the steel wire is wire pull-out, and the grip strength of the steel wire is greater than 28 MPa. When the grip length is greater than 100 mm, the failure mode of the steel wire is wire breakage, which is caused by reaching the breaking force of the steel wire. Therefore, this data cannot reflect the actual grip strength of the steel wire. The grip strength of conventional zinc-copper alloy is 15 MPa, while the grip strength performance of the anchoring material of the present invention is improved by more than 25%. Example 4

[0036] A casting device for hot-cast anchorage material for bridge cables according to Embodiments 1 to 3 includes a vertical positioning device 1 and a temperature control device 2; wherein: The vertical positioning device 1 includes an anchor cup connecting assembly 11 and a cable clamp 12. The anchor cup connecting assembly 11 has a two-part structure, with a cable hole I in the middle that mates with the cable body 3. The cable hole I is a regular hexagon, and the anchor cup connecting assembly 11 is connected to the small end of the conical hole of the anchor cup 4. The cable clamp 12 also has a two-part structure, clamping the cable body 3, with its top end vertically connected to the bottom end of the anchor cup connecting assembly 11. Because the anchor cup connecting assembly 11 and the cable clamp 12 are arranged vertically, this arrangement enables vertical positioning between the cable body 3 and the anchor cup 4, effectively solving the problems of eccentricity and bending stress between the cable body 3 and the anchor cup 4. This ensures uniform stress on the steel wire within the anchor cup 4, effectively improving the anchoring performance of the hot-cast anchor, and thus enhancing the anchoring performance and safety margin of the cable.

[0037] The anchor cup connection assembly 11 has a cross-shaped structure. The anchor cup connection assembly 11 is composed of two symmetrically arranged anchor cup connection units connected by bolt pair I 113. Each anchor cup connection unit includes an upper support plate 111 and an ear plate 112. The upper support plate 111 is arranged along the X-axis direction, and one end of the upper support plate 111 is provided with a connection hole for connecting with the small end of the cone hole of the anchor cup 4. The ear plate 112 is fixedly connected to the other end of the upper support plate 111 by welding along the Y-axis direction. The ear plate 112 is provided with bolt holes for installing the bolt pair I 113. The two symmetrically arranged anchor cup connection units each have half of the cable hole I in the middle of the end face where they are connected.

[0038] The cable clamp 12 includes two symmetrical crescent-shaped posts 121. The top of the crescent-shaped posts 121 is vertically connected to the bottom of the anchor cup connecting assembly 11 along the Z-axis. The outer side of the crescent-shaped posts 121 is semi-circular, and the inner side is provided with a continuous inner cavity that mates with the cable body 3. The cross-section of the continuous inner cavity is half a regular hexagon. Two or more rectangular ear plates 122 are fixedly connected to the crescent-shaped posts 121 along their axial direction. The two symmetrical crescent-shaped posts 121 are connected together by the rectangular ear plates 122 and bolts II 123 to form a cylindrical sleeve with cable holes II that mate with the cable body 3.

[0039] The temperature control device 2 is installed on the outside of the anchor cup 4. This device consists of a single dynamic insulation device 21, suitable for anchor cups with small lengths. The dynamic insulation device 21 and the anchor cup 4 cooperate to form a closed space. The dynamic insulation device 21 includes a cylindrical tube 211, a heating device 212, and a heat-conducting plate 213. The cylindrical tube 211 is circular, square, or other shapes. The upper and lower ends of the cylindrical tube 211 have holes that mate with the anchor cup 4, forming the closed space between the cylindrical tube 211 and the anchor cup 4. The heat-conducting plate 213 is fixedly connected to the inner wall of the cylindrical tube 211 and arranged spirally along the outer wall of the anchor cup 4. The heating device 212 is directly installed on the anchor cup 4 and uses a conventional resistance wire or other electric heating device. Each dynamic insulation device 21 also has two or more temperature sensors A214, which are mounted on the heat-conducting plate 213. During the casting of the anchoring material, a dynamic heat preservation device is activated to heat or maintain the temperature of the small end of the cone-shaped hole in the anchor cup. A temperature sensor controls the temperature of the anchor cup to a specific level, ensuring that the molten anchoring material completely fills the inner cavity of the small end of the anchor cup, increasing the density of the cast material. This dynamic heat preservation device heats or dissipates heat from the small end to the large end of the cone-shaped hole, solving the problem of high porosity during anchoring material casting, improving the density of the cast anchoring material, and enhancing anchoring efficiency. Example 5

[0040] A casting device for hot-cast anchorage material for bridge cables has the same basic structure as in Embodiment 4, including a vertical positioning device 1 and a temperature control device 2. The difference is that this casting device is suitable for anchor cups with larger length dimensions. The dynamic heat preservation device has three levels: a first-level dynamic heat preservation device, a second-level dynamic heat preservation device, and a third-level dynamic heat preservation device. The first-level dynamic heat preservation device is installed on the outer wall of the small end of the cone hole of the anchor cup, the second-level dynamic heat preservation device is installed on the outer wall of the middle part of the anchor cup, and the third-level dynamic heat preservation device is installed on the outer wall of the large end of the cone hole of the anchor cup.

[0041] The specific structure of the casting device for the hot-cast anchorage material of the bridge cable described in this embodiment five is as follows: A casting device for hot-cast anchorage material for bridge cables according to Embodiments 1 to 3 includes a vertical positioning device 1 and a temperature control device 2; wherein: The vertical positioning device 1 includes an anchor cup connecting assembly 11 and a cable clamp 12. The anchor cup connecting assembly 11 has a two-part structure, with a cable hole I in the middle that mates with the cable body 3. The cable hole I is a regular hexagon, and the anchor cup connecting assembly 11 is connected to the small end of the conical hole of the anchor cup 4. The cable clamp 12 also has a two-part structure, clamping the cable body 3, with its top end vertically connected to the bottom end of the anchor cup connecting assembly 11. Because the anchor cup connecting assembly 11 and the cable clamp 12 are arranged vertically, this arrangement enables vertical positioning between the cable body 3 and the anchor cup 4, effectively solving the problems of eccentricity and bending stress between the cable body 3 and the anchor cup 4. This ensures uniform stress on the steel wire within the anchor cup 4, effectively improving the anchoring performance of the hot-cast anchor, and thus enhancing the anchoring performance and safety margin of the cable.

[0042] The anchor cup connection assembly 11 has a cross-shaped structure. The anchor cup connection assembly 11 is composed of two symmetrically arranged anchor cup connection units connected by bolt pair I 113. Each anchor cup connection unit includes an upper support plate 111 and an ear plate 112. The upper support plate 111 is arranged along the X-axis direction, and one end of the upper support plate 111 is provided with a connection hole for connecting with the small end of the cone hole of the anchor cup 4. The ear plate 112 is fixedly connected to the other end of the upper support plate 111 by welding along the Y-axis direction. The ear plate 112 is provided with bolt holes for installing the bolt pair I 113. The two symmetrically arranged anchor cup connection units each have half of the cable hole I in the middle of the end face where they are connected.

[0043] The cable clamp 12 includes two symmetrical crescent-shaped posts 121. The top of the crescent-shaped posts 121 is vertically connected to the bottom of the anchor cup connecting assembly 11 along the Z-axis. The outer side of the crescent-shaped posts 121 is semi-circular, and the inner side is provided with a continuous inner cavity that mates with the cable body 3. The cross-section of the continuous inner cavity is half a regular hexagon. Two or more rectangular ear plates 122 are fixedly connected to the crescent-shaped posts 121 along their axial direction. The two symmetrical crescent-shaped posts 121 are connected together by the rectangular ear plates 122 and bolts II 123 to form a cylindrical sleeve with cable holes II that mate with the cable body 3.

[0044] The temperature control device 2 is installed on the outside of the anchor cup 4. This device consists of three dynamic insulation devices 21, suitable for anchor cups with large lengths. The dynamic insulation device has three levels: a first-level dynamic insulation device 21a, a second-level dynamic insulation device 21b, and a third-level dynamic insulation device 21c. The first-level dynamic insulation device 21a is installed on the outer wall of the small end of the cone hole of the anchor cup, the second-level dynamic insulation device 21b is installed on the outer wall of the middle part of the anchor cup, and the third-level dynamic insulation device 21c is installed on the outer wall of the large end of the cone hole of the anchor cup. Each dynamic insulation device 21 cooperates with the anchor cup 4 to form a closed space. The dynamic heat preservation device 21 includes a cylindrical tube 211, a heating device 212, and a heat-conducting plate 213. The cylindrical tube 211 is circular, square, or other shapes. The upper and lower ends of the cylindrical tube 211 are provided with holes that cooperate with the anchor cup 4, and the cylindrical tube 211 and the anchor cup 4 form the closed space. The heat-conducting plate 213 is fixedly connected to the inner wall of the cylindrical tube 211 and is arranged in a spiral shape along the outer wall of the anchor cup 4. The heating device 212 is directly installed on the anchor cup 4 and adopts a conventional electric heating device such as a resistance wire. Each dynamic heat preservation device 21 is also provided with two or more temperature sensors A214, which are installed on the heat-conducting plate 213. During the anchoring material casting process, the first-stage dynamic heat preservation device is activated to heat or maintain the temperature of the small end of the cone-shaped hole in the anchor cup. This ensures that the molten anchoring material completely fills the inner cavity of the small end of the anchor cup, increasing the density of the castable. After the anchoring material at the small end of the cone-shaped hole in the anchor cup is cast, the first-stage dynamic heat preservation device is closed, allowing for natural cooling. The second and third-stage dynamic heat preservation devices are then activated sequentially, continuously replenishing the voids in the lower end of the anchor cup. This process is repeated in the same order until all the anchoring material has solidified. This device heats or dissipates heat in stages from the small end of the cone-shaped hole in the anchor cup to the large end, which can solve the problem of a large porosity during anchoring material casting, improve the density of the cast anchoring material, and enhance anchoring efficiency.

[0045] As a variation of embodiments four and five, the heat-conducting plate 213 can also be arranged in an inclined or stepped manner along the outer wall of the anchor cup 4.

[0046] As a variation of Embodiment 5, the dynamic insulation device can also be configured as two-stage, four-stage, five-stage, etc., depending on the actual length of the anchor cup 4. Example 6

[0047] A casting device for hot-cast anchorage material for bridge cables, its basic structure is the same as in Embodiment 5, both including a vertical positioning device 1 and a temperature control device 2; the difference is that the dynamic heat preservation device 21 includes a sleeve 215, a temperature sensor B216, and a heat insulation layer 217. The sleeve 215 is a two-half structure connected together by bolts and fasteners. The inner wall of the sleeve 215 is tightly attached to the outer surface of the anchor cup 4, and the inner cavity of the sleeve 215 forms the closed space, in which a phase change material 6 is encapsulated. The phase change material 6 is a graphene-reinforced composite paraffin phase change material. The sleeve 215 is provided with a filling port 2151 and a pressure relief port 2152 that connect to its inner cavity. A heating resistance wire 218 is wound and installed on the outer surface of the sleeve 215. The temperature sensor B216 is installed on the inner wall of the sleeve 215. The heat insulation layer 217 is sleeved on the outside of the sleeve 215, and a cooling channel Q is provided between the heat insulation layer 217 and the sleeve 215. The cooling channel Q connects to the air inlet 2153 and the air outlet 2154 respectively.

[0048] The specific structure of the casting device for the hot-cast anchor material of the bridge cable described in Embodiment Six is ​​as follows: A casting device for hot-cast anchorage material for bridge cables according to Embodiments 1 to 3 includes a vertical positioning device 1 and a temperature control device 2; wherein: The vertical positioning device 1 includes an anchor cup connecting assembly 11 and a cable clamp 12. The anchor cup connecting assembly 11 has a two-part structure, with a cable hole I in the middle that mates with the cable body 3. The cable hole I is a regular hexagon, and the anchor cup connecting assembly 11 is connected to the small end of the conical hole of the anchor cup 4. The cable clamp 12 also has a two-part structure, clamping the cable body 3, with its top end vertically connected to the bottom end of the anchor cup connecting assembly 11. Because the anchor cup connecting assembly 11 and the cable clamp 12 are arranged vertically, this arrangement enables vertical positioning between the cable body 3 and the anchor cup 4, effectively solving the problems of eccentricity and bending stress between the cable body 3 and the anchor cup 4. This ensures uniform stress on the steel wire within the anchor cup 4, effectively improving the anchoring performance of the hot-cast anchor, and thus enhancing the anchoring performance and safety margin of the cable.

[0049] The anchor cup connection assembly 11 has a cross-shaped structure. The anchor cup connection assembly 11 is composed of two symmetrically arranged anchor cup connection units connected by bolt pair I 113. Each anchor cup connection unit includes an upper support plate 111 and an ear plate 112. The upper support plate 111 is arranged along the X-axis direction, and one end of the upper support plate 111 is provided with a connection hole for connecting with the small end of the cone hole of the anchor cup 4. The ear plate 112 is fixedly connected to the other end of the upper support plate 111 by welding along the Y-axis direction. The ear plate 112 is provided with bolt holes for installing the bolt pair I 113. The two symmetrically arranged anchor cup connection units each have half of the cable hole I in the middle of the end face where they are connected.

[0050] The cable clamp 12 includes two symmetrical crescent-shaped posts 121. The top of the crescent-shaped posts 121 is vertically connected to the bottom of the anchor cup connecting assembly 11 along the Z-axis. The outer side of the crescent-shaped posts 121 is semi-circular, and the inner side is provided with a continuous inner cavity that mates with the cable body 3. The cross-section of the continuous inner cavity is half a regular hexagon. Two or more rectangular ear plates 122 are fixedly connected to the crescent-shaped posts 121 along their axial direction. The two symmetrical crescent-shaped posts 121 are connected together by the rectangular ear plates 122 and bolts II 123 to form a cylindrical sleeve with cable holes II that mate with the cable body 3.

[0051] The temperature control device 2 is installed on the outside of the anchor cup 4. The temperature control device 2 consists of three dynamic heat preservation devices 21, which are suitable for anchor cups with large length dimensions. The three dynamic heat preservation devices are a first-level dynamic heat preservation device 21a, a second-level dynamic heat preservation device 21b, and a third-level dynamic heat preservation device 21c. The first-level dynamic heat preservation device 21a is installed on the outer wall of the small end of the cone hole of the anchor cup, the second-level dynamic heat preservation device 21b is installed on the middle outer wall of the anchor cup, and the third-level dynamic heat preservation device 21c is installed on the outer wall of the large end of the cone hole of the anchor cup.

[0052] Each dynamic insulation device 21 includes a sleeve 215, a temperature sensor B216, and a thermal insulation layer 217. The sleeve 215 is a two-part structure connected by bolts. The sleeve 215 is made of stainless steel with good thermal conductivity, high strength, high temperature resistance, and corrosion resistance. The inner wall of the sleeve 215 is tightly attached to the outer surface of the anchor cup 4, and the inner cavity of the sleeve 215 forms a closed space. The inner cavity encapsulates a phase change material 6. The phase change material 6 is a graphene-reinforced composite paraffin phase change material. This graphene-reinforced composite paraffin phase change material is a composite paraffin phase change material reinforced with graphene. Graphene can effectively improve the thermal conductivity of paraffin, making up for the lack of thermal conductivity of organic phase change materials. Moreover, the composite paraffin phase change material has a high latent heat of phase change, stable chemical properties, good safety, and relatively reasonable cost. Its phase change temperature can be precisely controlled at 180-220℃ by adjusting the ratio of paraffin and additives, matching the cooling requirements of the anchoring material. The sleeve 215 is provided with a filling port 2151 and a pressure relief port 2152 that connect to its inner cavity. A heating resistance wire 218 is wound and installed on the outer surface of the sleeve 215. The temperature sensor B216 is installed on the inner wall of the sleeve 215. The heat insulation layer is made of high-performance heat insulation materials such as ceramic fiber felt. The heat insulation layer 217 is sleeved on the outside of the sleeve 215, and a cooling channel Q is provided between the heat insulation layer 217 and the sleeve 215. The cooling channel Q is connected to the air inlet 2153 and the air outlet 2154 respectively.

[0053] Before casting the anchoring material, the phase change material is in a solid state, with a temperature close to the ambient temperature. When the high-temperature anchoring material is poured into the anchorage, the heat is rapidly transferred to the outer wall of the anchorage. The phase change material absorbs the heat dissipated by the anchoring material and begins to undergo a phase change, gradually transforming from a solid to a liquid state. During this process, it absorbs a large amount of latent heat, effectively slowing down the cooling rate of the anchoring material. Because the temperature of the phase change material remains basically constant during the phase change process, the anchoring material is in a relatively stable temperature environment for a certain period of time, which is conducive to its uniform solidification and reduces the generation of internal stress and shrinkage cavities.

[0054] As the anchoring material continues to cool, the temperature of the phase change material (PCM) begins to rise after completing its phase change. If the temperature exceeds the set upper limit, the temperature monitoring and feedback module triggers the air-cooling device to dissipate excess heat from the PCM into the environment, causing its temperature to drop. Conversely, if the anchoring material cools too quickly and its temperature falls below the set lower limit, the auxiliary heating device is activated to maintain the PCM temperature, ensuring a smooth cooling process. The entire process is controlled in real-time by the temperature monitoring and feedback module to ensure that the anchoring material cools to room temperature according to the designed temperature curve and completes solidification.

[0055] As a variation of Embodiment Six, for ease of assembly and disassembly, the sleeve 215 can also be configured as a two-half structure and connected by bolt pairs to form a whole. Example 6

[0056] A method for casting hot-cast anchorage material for bridge cables, the method using the casting apparatus described in Example 5, includes the following steps: S1. Prepare the anchoring material molten liquid; S2. Remove the PE layer of the cable: Shape the steel wire cable into a regular hexagonal shape, determine the length of the cable at both ends installed in the anchor cup, mark the small end of the cone hole of the anchor cup, and remove the PE layer of the steel wire cable of the anchoring section. S3. Cable body wire positioning: After the cable body, anchor cup, hot-cast anchoring material, wire splitting plate and vertical positioning device are ready, the steel wires of the cable body are sequentially inserted into the inner cavity of the anchor cup and the wire splitting plate. After each steel wire is inserted into the wire splitting plate for dispersion and positioning, some steel wires are truncated, and the wire splitting plate is installed on the inner cavity of the large end of the cone hole of the anchor cup. S4. Install the vertical positioning device: Install the vertical positioning device according to the markings, use screws to connect the upper support plate to the anchor cup, tighten bolt width I and bolt width II on the vertical positioning device, fix the steel wire cable, and ensure that the cable and the anchor cup are always in a vertical state. S5. Preheating: The temperature control device is fitted onto the outside of the anchor cup, and the anchor cup and the cable body inside the anchor cup are preheated by the heating device of the dynamic heat preservation device. The preheating temperature of the anchor cup is 250-350℃; at the same time, the anchoring material is heated to a temperature of 430-460℃. S6. Casting of Anchoring Material: After the anchor cup temperature and the anchoring material temperature reach the required levels, pour the high-temperature anchoring material from the large end of the cone hole of the anchor cup into the inner cone cavity containing the wire rope body; at the same time, turn on the heating device of the first-stage dynamic heat preservation device, observe the temperature sensor, and after the set temperature is reached, turn off the heating device of the first-stage dynamic heat preservation device. After casting is completed, cool it by natural cooling; then, in the same steps, turn on and off the heating devices of the second and third-stage dynamic heat preservation devices in sequence until the hot-cast anchoring material is completely solidified; S7. Perform a top pressure test or an over-tension test on the anchor cup. Example 7

[0057] A method for casting hot-cast anchorage material for bridge cables, the method using the casting apparatus described in Example 6, includes the following steps: S1. Preparation of anchoring material melt: The amount of material to be prepared is calculated based on the theoretical amount and theoretical burn-off rate; S2. Remove the PE layer of the cable: Shape the steel wire cable into a regular hexagonal shape, determine the length of the cable at both ends installed in the anchor cup, mark the small end of the cone hole of the anchor cup, and remove the PE layer of the steel wire cable of the anchoring section. S3. Cable body wire positioning: After the cable body, anchor cup, hot-cast anchoring material, wire splitting plate and vertical positioning device are ready, the steel wires of the cable body are sequentially inserted into the inner cavity of the anchor cup and the wire splitting plate. After each steel wire is inserted into the wire splitting plate for dispersion and positioning, some steel wires are truncated, and the wire splitting plate is installed on the inner cavity of the large end of the cone hole of the anchor cup. S4. Install the vertical positioning device: Install the vertical positioning device according to the markings, use screws to connect the upper support plate to the anchor cup, tighten bolt width I and bolt width II on the vertical positioning device, fix the steel wire cable, and ensure that the cable and the anchor cup are always in a vertical state. S5. Preheating: Heat the anchoring material at a temperature of 430–460℃; S6. Casting of Anchoring Material: Once the anchoring material reaches the required temperature, the heated anchoring material is poured from the large end of the conical hole in the anchor cup into the inner conical cavity containing the wire rope body. Simultaneously, the first-stage dynamic heat preservation device is activated, and the phase change material begins to absorb heat from the anchoring material, slowing down the cooling rate of the anchoring material. As the anchoring material continues to cool, the temperature of the phase change material begins to rise after completing the phase change. If the temperature sensor detects that the temperature exceeds the preset upper limit, the fan is activated to dissipate the excess heat of the phase change material into the environment, causing its temperature to drop. Conversely, if the anchoring material cools too quickly and the temperature of the phase change material falls below the set lower limit, resistance wire heating is activated to maintain the temperature of the phase change material, ensuring that the cooling process of the anchoring material proceeds smoothly until solidification, and the first-stage dynamic heat preservation device is closed. The same steps are then repeated to activate the second and third-stage dynamic heat preservation devices sequentially until all the hot-cast anchoring material has solidified. S7. Perform a top pressure test or an over-tension test on the anchor cup.

Claims

1. A hot-cast anchoring material for bridge cables, characterized in that, Its chemical composition by mass percentage includes: Cu: 1.8%–2.2%, Ti: 0.2%–0.5%, Mg: 0.01%–0.05%, with the remainder being Zn and unavoidable impurities; among which unavoidable impurities Fe≤0.01% and Pb≤0.003%.

2. A casting device for hot-cast anchorage material for bridge cables as described in claim 1, characterized in that, It includes a vertical positioning device (1); the vertical positioning device (1) includes an anchor cup connecting assembly (11) and a cable clamp (12). The anchor cup connecting assembly (11) is a two-part structure. The middle part of the anchor cup connecting assembly (11) is provided with a cable hole I that cooperates with the cable body (3). The anchor cup connecting assembly (11) is connected to the small end of the cone hole of the anchor cup (4). The cable clamp (12) is a two-part structure. The cable clamp (12) is clamped outside the cable body (3), and the top end of the cable clamp (12) is vertically connected to the bottom end of the anchor cup connecting assembly (11).

3. The casting device for hot-cast anchorage material for bridge cables according to claim 2, characterized in that, The anchor cup connection assembly (11) has a cross-shaped structure. The anchor cup connection assembly (11) is composed of two symmetrically arranged anchor cup connection units connected by bolt pair I (113). Each anchor cup connection unit includes an upper support plate (111) and an ear plate (112). The upper support plate (111) is arranged along the X-axis direction. One end of the upper support plate (111) is provided with a connection hole for connecting with the small end of the cone hole of the anchor cup (4). The ear plate (112) is fixedly connected to the other end of the upper support plate (111) along the Y-axis direction. The ear plate (112) is provided with bolt holes for installing the bolt pair I (113). The two symmetrically arranged anchor cup connection units each have half of the cable hole I in the middle of the end face where they are connected.

4. The casting device for hot-cast anchorage material for bridge cables according to claim 2, characterized in that, The cable clamp (12) includes two symmetrical crescent-shaped posts (121). The top of the crescent-shaped post (121) is vertically connected to the bottom of the anchor cup connecting assembly (11) along the Z-axis. The crescent-shaped post (121) has a continuous inner cavity that mates with the cable body (3). Two or more rectangular ear plates (122) are fixedly connected to the crescent-shaped post (121) along its axial direction. The two symmetrical crescent-shaped posts (121) are connected together through the rectangular ear plates (122) and bolt width II (123) to form a cylindrical sleeve with a cable hole II that mates with the cable body (3).

5. The casting device for hot-cast anchorage material for bridge cables according to claim 2, characterized in that, The casting device also has a temperature control device (2) installed on the outside of the anchor cup (4). The temperature control device (2) includes at least one dynamic heat preservation device (21), and each dynamic heat preservation device (21) cooperates with the anchor cup (4) to form a closed space.

6. The casting device for hot-cast anchorage material for bridge cables according to claim 5, characterized in that, The dynamic heat preservation device consists of three parts: a first-stage dynamic heat preservation device (21a), a second-stage dynamic heat preservation device (21b), and a third-stage dynamic heat preservation device (21c). The first-stage dynamic heat preservation device (21a) is installed on the outer wall of the small end of the cone hole of the anchor cup (4), the second-stage dynamic heat preservation device (21b) is installed on the outer wall of the middle part of the anchor cup (4), and the third-stage dynamic heat preservation device (21c) is installed on the outer wall of the large end of the cone hole of the anchor cup (4).

7. The casting device for hot-cast anchorage material for bridge cables according to claim 6, characterized in that, The dynamic heat preservation device (21) includes a cylindrical tube (211), a heating device (212), and a heat-conducting plate (213). The upper and lower ends of the cylindrical tube (211) are provided with holes that cooperate with the anchor cup (4), and the cylindrical tube (211) and the anchor cup (4) form the closed space. The heat-conducting plate (213) is fixedly connected to the inner wall of the cylindrical tube (211) and is arranged in a spiral, inclined or stepped manner along the outer wall of the anchor cup (4). The heating device (212) is directly installed on the anchor cup (4). Each dynamic heat preservation device (21) is also provided with two or more temperature sensors A (214), which are installed on the heat-conducting plate (213).

8. The casting device for hot-cast anchorage material for bridge cables according to claim 6, characterized in that, The dynamic heat preservation device (21) includes a sleeve (215), a temperature sensor B (216), and a heat insulation layer (217). The inner wall of the sleeve (215) is tightly fitted to the outer surface of the anchor cup (4), and the inner cavity of the sleeve (215) forms the closed space. The inner cavity is encapsulated with a phase change material (6). The phase change material (6) is a graphene-reinforced composite paraffin phase change material. The sleeve (215) is provided with a filling port (2151) that connects to its inner cavity. The sleeve (215) has a pressure relief port (2152) and a heating resistance wire (218) wound around the outer surface of the sleeve (215); the temperature sensor B (216) is installed on the inner wall of the sleeve (215); the heat insulation layer (217) is sleeved on the outside of the sleeve (215), and a cooling channel (Q) is provided between the heat insulation layer (217) and the sleeve (215), which is connected to the air inlet (2153) and the air outlet (2154) respectively.

9. A method for casting hot-cast anchorage material for bridge cables, characterized in that, The method, employing the casting apparatus of claim 7, includes the following steps: S1. Prepare the anchoring material molten liquid; S2. Remove the PE layer of the cable: Remove the PE layer of the steel wires from the anchor sections at both ends of the cable; S3. Positioning of steel wires in the anchor cup: After the PE layer has been removed, the steel wires are sequentially inserted into the inner cavity of the anchor cup and the wire splitting plate. Each steel wire is inserted into the wire splitting plate for dispersion and positioning. Some steel wires are then truncated, and the wire splitting plate is installed on the inner cavity of the large end of the cone hole of the anchor cup. S4. Install the vertical positioning device: After installing the vertical positioning device, connect the upper support plate to the anchor cup, tighten bolt width I and bolt width II on the vertical positioning device, fix the steel wire cable, and ensure that the cable and the anchor cup are always in a vertical state. S5. Preheating: The temperature control device is fitted onto the outside of the anchor cup, and the anchor cup and the cable body inside the anchor cup are preheated by the heating device of the dynamic heat preservation device. The preheating temperature of the anchor cup is 250-350℃; at the same time, the anchoring material is heated to a temperature of 430-460℃. S6. Casting of Anchoring Material: After the anchor cup temperature and the anchoring material temperature reach the required levels, pour the high-temperature anchoring material from the large end of the cone hole of the anchor cup into the inner cone cavity containing the wire rope body; at the same time, turn on the heating device of the first-stage dynamic heat preservation device, observe the temperature sensor, and after the set temperature is reached, turn off the heating device of the first-stage dynamic heat preservation device. After casting is completed, cool it by natural cooling; then, in the same steps, turn on and off the heating devices of the second and third-stage dynamic heat preservation devices in sequence until the hot-cast anchoring material is completely solidified; S7. Perform a top pressure test or an over-tension test on the anchor cup.

10. A method for casting hot-cast anchorage material for bridge cables, characterized in that, The method, employing the casting apparatus of claim 8, includes the following steps: S1. Prepare the anchoring material molten liquid; S2. Remove the PE layer of the cable: Remove the PE layer of the steel wires from the anchor sections at both ends of the cable; S3. Positioning of steel wires in the anchor cup: After the PE layer has been removed, the steel wires are sequentially inserted into the inner cavity of the anchor cup and the wire splitting plate. Each steel wire is inserted into the wire splitting plate for dispersion and positioning. Some steel wires are then truncated, and the wire splitting plate is installed on the inner cavity of the large end of the cone hole of the anchor cup. S4. Install the vertical positioning device: After installing the vertical positioning device, connect the upper support plate to the anchor cup, tighten bolt width I and bolt width II on the vertical positioning device, fix the steel wire cable, and ensure that the cable and the anchor cup are always in a vertical state. S5. Preheating: Heat the anchoring material at a temperature of 430–460℃; S6. Casting of Anchoring Material: Once the anchoring material reaches the required temperature, the heated anchoring material is poured from the large end of the conical hole in the anchor cup into the inner conical cavity containing the wire rope body. Simultaneously, the first-stage dynamic heat preservation device is activated, and the phase change material begins to absorb heat from the anchoring material, slowing down the cooling rate of the anchoring material. As the anchoring material continues to cool, the temperature of the phase change material begins to rise after completing the phase change. If the temperature sensor detects that the temperature exceeds the preset upper limit, the fan is activated to dissipate the excess heat of the phase change material into the environment, causing its temperature to drop. Conversely, if the anchoring material cools too quickly and the temperature of the phase change material falls below the set lower limit, resistance wire heating is activated to maintain the temperature of the phase change material, ensuring that the cooling process of the anchoring material proceeds smoothly until solidification, and the first-stage dynamic heat preservation device is closed. The same steps are then repeated to activate the second and third-stage dynamic heat preservation devices sequentially until all the hot-cast anchoring material has solidified. S7. Perform a top pressure test or an over-tension test on the anchor cup.

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