Cast-in-place and prefabrication combined wind power foundation manufacturing device

Abstract

The invention provides a cast-in-place and prefabrication combined wind power foundation manufacturing device, and relates to the technical field of wind power foundation construction. The cast-in-place and prefabrication combined wind power foundation manufacturing device comprises a core tube formwork system, a flange plate formwork system and a bottom support and buttress system. The core tube formwork system is composed of a core column outer mold and a core column inner mold which are concentrically arranged, and an annular gap for pouring a core tube is formed. The flange template system is fixed at the top end of the core tube template; the bottom support provides vertical support, and the buttress system is distributed in the circumferential direction of the flange plate formwork. Reinforcing section bars are arranged at key positions of the formwork, and the core column outer formwork and the core column inner formwork are provided with corresponding door openings for construction to enter and exit. The mode that the cast-in-place core tube and the prefabricated buttress are combined is adopted, the precision and stability of the foundation structure are improved, construction operation is convenient, the durability and construction efficiency of the formwork are improved, and material waste and cost are reduced.

Description

Technical Field

[0001] This invention relates to the field of wind power foundation construction technology, specifically to a wind power foundation fabrication device that combines cast-in-place and prefabricated construction. Background Technology

[0002] As a critical supporting structure for wind turbine generators, the quality of wind turbine foundations directly affects the stability and service life of the turbines. Currently, the industry primarily uses reinforced concrete for wind turbine foundations, constructed through cast-in-place construction. The specific process involves first building a formwork system according to the design dimensions, tying the reinforcing steel frame, then pouring concrete into the formwork, curing it to the design strength, and finally removing the formwork to form a foundation structure that meets load-bearing requirements. This structure must withstand complex forces such as the load from the wind turbine's upper structure, wind loads, and seismic loads. Therefore, the requirements for concrete forming precision, strength, and durability are extremely high. The supporting role and forming control of the formwork system before the concrete solidifies are particularly crucial.

[0003] The existing cast-in-place wind turbine foundation formwork system has obvious defects: traditional formwork is assembled in a scattered manner, the connection accuracy between the core tube and the flange is low, which easily leads to structural eccentricity; the formwork is not rigid enough and is easily deformed under the lateral pressure of concrete, which affects the verticality of the core tube and the flatness of the flange, increasing the difficulty of wind turbine installation; there is a lack of dedicated construction access, which makes it inconvenient for personnel to work and makes it difficult to ensure construction quality.

[0004] To address this, we have developed a new wind power foundation fabrication device that combines cast-in-place and prefabricated construction. Summary of the Invention

[0005] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a wind power foundation fabrication device that combines cast-in-place and prefabricated construction. This solves the problems in existing technologies, such as low connection accuracy of the formwork system leading to easy eccentricity of the foundation structure, insufficient rigidity causing easy deformation under concrete lateral pressure, and lack of dedicated construction channels affecting work quality.

[0006] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: a wind power foundation fabrication device combining cast-in-place and prefabricated construction, comprising a core tube template system, a flange template system, and a bottom support and buttress system; The core tube formwork system is located at the bottom of the device. The core tube formwork system includes an outer core column formwork and an inner core column formwork. The outer core column formwork and the inner core column formwork are concentrically arranged, forming an annular gap between them for pouring core tube concrete. The flange template system includes an outer flange mold and an inner flange mold, which are respectively fixedly installed on the top of the outer core column mold and the inner core column mold. The bottom support is located at the very bottom of the device and is fixedly connected to the bottom of the core tube template system, providing vertical support for the entire device; The buttress system is arranged at equal angular intervals around the flange template system, and its inner side is in contact with the outer wall of the flange outer mold.

[0007] Preferably, the outer mold of the core column includes a cylindrical outer mold panel, a first doorway module is provided on the periphery of the outer mold panel, outer template ribs are distributed vertically at intervals on the outer side of the outer mold panel, the outer template ribs are perpendicular to the surface of the outer mold panel and are welded and fixed to the outer mold panel; outer template connecting plate side plates are arranged horizontally between adjacent outer template ribs, the two ends of the outer template connecting plate side plates are welded to the outer template ribs, and a mudguard is fixedly installed at the bottom of the outer mold panel.

[0008] Preferably, the inner mold of the core column includes a cylindrical inner mold panel, a second doorway module is provided on the periphery of the inner mold panel, inner mold ribs are distributed vertically at intervals on the inner side of the inner mold panel, the inner mold ribs are perpendicular to the surface of the inner mold panel and are welded and fixed to the inner mold panel, and an inner mold connecting plate is arranged horizontally between adjacent inner mold ribs, with both ends of the inner mold connecting plate welded to the inner mold ribs.

[0009] Preferably, both the outer mold panel and the inner mold panel are equipped with reinforcing profiles at the mold pulling holes, and the reinforcing profiles are made of 8# channel steel of Q235 material.

[0010] Preferably, the first doorway module and the second doorway module are positioned and matched in size, together forming a passage for construction personnel to enter and exit the annular gap of the core tube formwork system.

[0011] Preferably, the flange outer mold is in the shape of an annular step, and flange outer ribs are fixed at vertical intervals on the outer side of the flange outer mold. A flange outer connecting plate is arranged horizontally between two adjacent flange outer ribs. The two ends of the flange outer connecting plate are welded to the flange outer ribs, and a clamp is fitted on the outer side of the flange outer mold body.

[0012] Preferably, the flange inner mold includes an annular inner mold body and a circumferentially arranged operating platform assembly. Flange inner ribs are fixedly fixed at vertical intervals along the inner side of the annular inner mold body. Flange inner connecting plates are horizontally arranged between two adjacent flange inner ribs. The two ends of the flange inner connecting plates are welded to the flange inner ribs. The operating platform assembly is fixedly installed on the top of the core column inner mold. The surface of the operating platform assembly is covered with anti-slip steel plates.

[0013] Preferably, the outer mold panel, inner mold panel, flange outer mold body, and annular inner mold body are all integrally formed from Q355 steel plate with a thickness of 4mm. The outer template rib plate, inner mold rib plate, flange outer rib plate, and flange inner rib plate are all made of Q235 steel plate with a thickness of 10mm. The outer template connecting plate side plate, inner mold connecting plate, flange outer connecting plate, and flange inner connecting plate are all made of Q235 steel plate with a thickness of 14mm.

[0014] (III) Beneficial Effects This invention provides a wind turbine foundation fabrication device that combines cast-in-place and prefabricated construction, which has the following beneficial effects: 1. This wind power foundation fabrication device, which combines cast-in-place and precast construction, ensures uniform wall thickness and verticality of the core tube after casting by using the concentric setting and rigid structure of the core tube template system, avoiding eccentric stress and improving the foundation's load-bearing stability; the flange template is precisely connected to the core tube template to ensure the flatness of the flange and reduce the difficulty of subsequent wind turbine installation.

[0015] 2. This wind turbine foundation fabrication device, combining cast-in-place and precast components, utilizes dedicated portal modules to create construction access, facilitating personnel movement and ensuring the quality of rebar tying and concrete vibration. The precast buttress system improves construction efficiency, reduces material waste, and lowers costs. Attached Figure Description

[0016] Figure 1 This is a cross-sectional view of the present invention; Figure 2 This is a perspective view of the present invention after the bottom support has been removed; Figure 3 This is a front view of the present invention after the bottom support has been removed; Figure 4 This is a structural schematic diagram of the inner mold of the core column and the inner mold of the flange.

[0017] The components include: 1. Core tube formwork system; 2. Flange formwork system; 3. Bottom support; 4. Buttress system; 5. Core column outer formwork; 6. Core column inner formwork; 7. Flange outer formwork; 8. Flange inner formwork; 9. Outer formwork panel; 10. First doorway module; 11. Outer formwork ribs; 12. Outer formwork connecting plate side plate; 13. Inner formwork panel; 14. Second doorway module; 15. Inner formwork stiffening plate; 16. Inner formwork connecting plate; 17. Reinforcing profile; 18. Flange outer ribs; 19. Flange outer connecting plate; 20. Clamps; 21. Annular inner formwork body; 22. Operating platform assembly; 23. Flange inner ribs; 24. Flange inner connecting plate; 25. Anti-slip steel plate; 26. Mudguard. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Examples, such as Figure 1 - Figure 4 As shown, this embodiment of the invention provides a wind power foundation fabrication device combining cast-in-place and prefabricated construction, including a core tube template system 1, a flange template system 2, a bottom support 3, and a buttress system 4. Through the coordinated operation of these four systems, the device achieves a hybrid construction mode of "cast-in-place core tube + prefabricated buttress" for wind power foundations. The core tube and flange serve as the load-bearing core of the foundation, and the cast-in-place process ensures the integrity of the structure. The prefabrication of the buttress system 4 can improve installation efficiency. The overall design not only meets the strength requirements of the wind turbine for the foundation but also reduces the amount of concrete used, solving the problems of material waste and long construction cycle of traditional cast-in-place foundations.

[0020] Specifically, the core tube formwork system 1 is located at the bottom of the device. The core tube formwork system 1 includes the outer core column formwork 5 and the inner core column formwork 6. The outer core column formwork 5 and the inner core column formwork 6 are set concentrically, forming an annular gap between them for pouring the core tube concrete. The core tube is a key structure for transferring the upper load to the foundation. The size of the annular gap needs to match the design bearing capacity. The concentric setting can ensure that the core tube wall thickness is uniform after pouring and avoid stress concentration caused by eccentricity. The closed space formed by the outer core column formwork 5 and the inner core column formwork 6 can constrain the concrete flow and control the loss of moisture, reducing the occurrence of cracks. At the same time, the rigidity of the metal formwork ensures that the verticality and cylindricity of the core tube meet the installation requirements. The flange template system 2 includes an outer flange mold 7 and an inner flange mold 8, which are respectively fixedly installed on the top of the outer core column mold 5 and the inner core column mold 6. Bottom support 3 is located at the bottom of the device and is fixedly connected to the bottom of the core tube formwork system 1. It provides vertical support for the entire device. Bottom support 3 is in direct contact with the foundation and bears the weight of the entire device and the concrete during the pouring process. It prevents the formwork from settling and deforming and ensures the positional accuracy of the core tube and flange. The buttress system 4 is arranged at equal angles around the flange template system 2, and its inner side is in contact with the outer wall of the flange outer mold 7. The buttress system 4 is set around the lower structure of the flange. Through the contact connection with the flange outer mold 7, it enhances the lateral force resistance of the lower structure of the flange. The prefabricated buttress template can be installed quickly. The bottom adjusting bolts can adapt to installation errors, ensure the coordinated force bearing of the buttress and the lower structure of the flange, and improve the overall anti-overturning performance of the foundation.

[0021] Specifically, the outer formwork 5 of the core column includes a cylindrical outer formwork panel 9, with a first doorway module 10 on the periphery of the outer formwork panel 9. Outer formwork ribs 11 are vertically spaced along the outer side of the outer formwork panel 9, perpendicular to the surface of the outer formwork panel 9 and welded to it. A horizontal outer formwork connecting plate side plate 12 is arranged between adjacent outer formwork ribs 11, with both ends of the outer formwork connecting plate side plate 12 welded to the outer formwork ribs 11. A mudguard 26 is fixedly installed at the bottom of the outer formwork panel 9. The outer formwork panel 9 provides a forming reference for the outer side of the core tube, the first doorway module 10 allows construction personnel to enter and exit, the outer formwork ribs 11 and the outer formwork connecting plate side plate 12 form a grid support structure to resist the lateral pressure of the concrete, and the mudguard 26 prevents soil from entering the formwork. The core column inner mold 6 includes a cylindrical inner mold panel 13. A second doorway module 14 is provided around the inner mold panel 13. Inner mold reinforcing plates 15 are distributed vertically at intervals on the inner side of the inner mold panel 13. The inner mold reinforcing plates 15 are perpendicular to the surface of the inner mold panel 13 and are welded and fixed to the inner mold panel 13. Inner mold connecting plates 16 are arranged horizontally between adjacent inner mold reinforcing plates 15. The two ends of the inner mold connecting plates 16 are welded to the inner mold reinforcing plates 15. The inner mold panel 13 and the outer mold panel 9 cooperate to form the pouring space inside the core tube. The supporting structure of the inner mold reinforcing plates 15 and the inner mold connecting plates 16 ensures that the core column inner mold 6 does not deform under concrete pressure. The second doorway module 14 and the first doorway module 10 correspond to form a working channel to facilitate construction operations. Both the outer mold panel 9 and the inner mold panel 13 are equipped with reinforcing profiles 17 at the pull-out holes. The reinforcing profiles 17 are made of 8# channel steel of Q235 material. The reinforcing profiles 17 enhance the strength of the panel around the pull-out holes, ensuring that the panel does not deform when the tie bolts are tightened, and ensuring the dimensional accuracy of the core tube. The first portal module 10 and the second portal module 14 are positioned and matched in size, together forming a passage for construction personnel to enter and exit the annular gap of the core tube formwork system 1. This passage provides operating space for construction personnel, facilitating operations such as rebar tying and concrete vibration, and ensuring the construction quality of the core tube. The outer flange mold 7 is in the shape of an annular step. The outer flange mold 7 is fixed with flange outer ribs 18 at vertical intervals on the outer side. The flange outer connecting plate 19 is arranged horizontally between two adjacent flange outer ribs 18. The two ends of the flange outer connecting plate 19 are welded to the flange outer ribs 18. The outer flange mold 7 is fitted with a clamp 20 on the outer side of the body. The flange inner mold 8 includes an annular inner mold body 21 and a circumferentially arranged operating platform assembly 22. The operating platform assembly 22 provides a working surface for flange construction. Flange inner ribs 23 are fixed vertically at intervals on the inner side of the annular inner mold body 21. Flange inner connecting plates 24 are arranged horizontally between two adjacent flange inner ribs 23. The two ends of the flange inner connecting plates 24 are welded to the flange inner ribs 23. The operating platform assembly 22 is fixedly installed on the top of the core column inner mold 6. Anti-slip steel plates 25 are laid on the surface of the operating platform assembly 22. The outer mold panel 9, inner mold panel 13, flange outer mold body 7 and annular inner mold body 21 are all integrally formed from Q355 steel plate with a thickness of 4mm. The outer mold rib plate 11, inner mold rib plate 15, flange outer rib plate 18 and flange inner rib plate 23 are all made of Q235 steel plate with a thickness of 10mm. The outer mold connecting plate side plate 12, inner mold connecting plate 16, flange outer connecting plate 19 and flange inner connecting plate 24 are all made of Q235 steel plate with a thickness of 14mm. Working principle: During installation, the bottom support 3 is first placed on the foundation and leveled. Then, the outer mold 5 and inner mold 6 of the core column are hoisted onto the bottom support 3 and fixed with connectors, and their concentricity is adjusted. Next, the outer mold 7 and inner mold 8 of the flange are fixedly installed on the top of the outer mold 5 and inner mold 6 of the core column, respectively, to ensure accurate positioning. Finally, the buttress system 4 is evenly installed around the outer mold 7 of the flange, and the verticality is adjusted with the bottom adjusting bolts to complete the installation of the entire device. During concrete pouring, workers enter the annular gap between the outer formwork 5 and the inner formwork 6 of the core column, utilizing the passage formed by the first portal module 10 and the second portal module 14. They then tie the core tube reinforcement cage according to design requirements, ensuring that the reinforcement spacing and protective layer thickness meet specifications. Simultaneously, reinforcement nodes for connection to the flange are reserved. After tying, the stability and positional accuracy of the reinforcement cage are checked. Once the reinforcement tying is accepted, concrete is poured into the annular gap between the outer formwork 5 and the inner formwork 6 of the core column using a pump. During pouring, a vibrator is used to ensure the concrete is dense and free of air bubbles. The pouring height is strictly controlled, stopping at the lower part of the flange formwork system 2, without entering the enclosed area of ​​the flange formwork system 2, reserving connection space for subsequent flange installation. After pouring, curing is performed. Once the concrete reaches the design strength, the inner formwork, outer formwork, and flange formwork are removed sequentially to complete the core tube construction. This device utilizes the high rigidity of metal formwork and the excellent plasticity of fluid concrete to precisely shape the concrete before it hardens, ensuring the accuracy of the foundation's formation. Simultaneously, the device's excellent sealing properties effectively control moisture loss from the concrete, reducing surface cracking after hardening. Furthermore, the device's design fully adheres to mechanical principles, optimizing the structural stress distribution to significantly reduce material usage while meeting the load-bearing requirements of wind power foundations, achieving a balance between lightweight design and high strength.

[0022] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A wind turbine foundation fabrication device combining cast-in-place and prefabricated construction, characterized in that: It includes a core tube formwork system (1), a flange formwork system (2), bottom support (3) and a buttress system (4); The core tube formwork system (1) is located at the lower part of the device. The core tube formwork system (1) includes a core column outer formwork (5) and a core column inner formwork (6). The core column outer formwork (5) and the core column inner formwork (6) are concentrically arranged, and an annular gap is formed between them for pouring core tube concrete. The flange template system (2) includes an outer flange mold (7) and an inner flange mold (8), which are respectively fixedly installed on the top of the outer core column mold (5) and the inner core column mold (6); The bottom support (3) is located at the bottom of the device and is fixedly connected to the bottom of the core tube template system (1) to provide vertical support for the whole device; The buttress system (4) is arranged at equal angular intervals around the flange template system (2), and its inner side is in contact with the outer wall of the flange outer mold (7).

2. The wind turbine foundation fabrication device combining cast-in-place and prefabricated construction according to claim 1, characterized in that: The core column outer mold (5) includes a cylindrical outer mold panel (9), a first doorway module (10) is provided on the periphery of the outer mold panel (9), and outer template ribs (11) are distributed vertically at intervals on the outer side of the outer mold panel (9). The outer template ribs (11) are perpendicular to the surface of the outer mold panel (9) and are welded and fixed to the outer mold panel (9). The outer template connecting plate side plate (12) is arranged horizontally between adjacent outer template ribs (11). The two ends of the outer template connecting plate side plate (12) are welded to the outer template ribs (11). A mudguard (26) is fixedly installed at the bottom of the outer mold panel (9).

3. The wind turbine foundation fabrication device combining cast-in-place and prefabricated construction according to claim 2, characterized in that: The core column inner mold (6) includes a cylindrical inner mold panel (13). The inner mold panel (13) has a second doorway module (14) on its periphery. The inner mold panel (13) has inner mold ribs (15) distributed vertically at intervals on its inner side. The inner mold ribs (15) are perpendicular to the surface of the inner mold panel (13) and are welded and fixed to the inner mold panel (13). The inner mold connecting plates (16) are arranged horizontally between adjacent inner mold ribs (15). The two ends of the inner mold connecting plates (16) are welded to the inner mold ribs (15).

4. The wind turbine foundation fabrication device combining cast-in-place and prefabricated construction according to claim 3, characterized in that: The outer mold panel (9) and the inner mold panel (13) are both equipped with reinforcing profiles (17) at the mold holes. The reinforcing profiles (17) are made of 8# channel steel of Q235 material.

5. The wind turbine foundation fabrication device combining cast-in-place and prefabricated construction according to claim 4, characterized in that: The first doorway module (10) and the second doorway module (14) are positioned and matched in size, forming a passage for construction personnel to enter and exit the annular gap of the core tube formwork system (1).

6. The wind turbine foundation fabrication device combining cast-in-place and prefabricated construction according to claim 5, characterized in that: The flange outer mold (7) is in the shape of annular steps. Flange outer ribs (18) are fixed vertically at intervals on the outer side of the flange outer mold (7). Flange outer connecting plates (19) are arranged horizontally between two adjacent flange outer ribs (18). The two ends of the flange outer connecting plates (19) are welded to the flange outer ribs (18). A clamp (20) is fitted on the outer side of the flange outer mold (7).

7. The wind turbine foundation fabrication device combining cast-in-place and prefabricated construction according to claim 6, characterized in that: The flange inner mold (8) includes an annular inner mold body (21) and a circumferentially arranged operating platform assembly (22). The inner side of the annular inner mold body (21) is fixed with flange inner ribs (23) at vertical intervals. A flange inner connecting plate (24) is arranged horizontally between two adjacent flange inner ribs (23). The two ends of the flange inner connecting plate (24) are welded to the flange inner ribs (23). The operating platform assembly (22) is fixedly installed on the top of the core column inner mold (6). The surface of the operating platform assembly (22) is covered with anti-slip steel plate (25).

8. The wind turbine foundation fabrication device combining cast-in-place and prefabricated construction according to claim 7, characterized in that: The outer mold panel (9), inner mold panel (13), flange outer mold (7) body and annular inner mold body (21) are all integrally formed from Q355 steel plate with a thickness of 4mm. The outer template rib (11), inner mold rib (15), flange outer rib (18) and flange inner rib (23) are all made from Q235 steel plate with a thickness of 10mm. The outer template connecting plate side plate (12), inner mold connecting plate (16), flange outer connecting plate (19) and flange inner connecting plate (24) are all made from Q235 steel plate with a thickness of 14mm.

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