Intelligent prefabrication construction method for railway box girder

Abstract

The invention discloses a railway box girder intelligent prefabrication construction method, and relates to the technical field of railway box girder intelligent prefabrication construction. The method comprises the steps that a plurality of machining management units which are high in intelligent degree and can be coordinated and matched with one another are constructed; based on cooperation of all the processing management units, corresponding box girder formwork installation is conducted; the box girder formworks at least comprise two types, and the types of the box girder formworks of the two types can be adjusted through the side formwork chamfering formworks which can be replaced with each other. According to the engineering requirements, the machined steel bars are conveyed to the steel bar binding mould to be bound, the steel bar framework formed through binding is obtained, and the steel bar conflict problem is solved through BIM modeling in the process. According to the method, by means of intelligent means, the construction efficiency is improved, and the box girder prefabricating period is more effectively shortened; by arranging the side die chamfering templates which can be replaced mutually, the purpose that the forming size of the box girder template can be globally changed only by replacing local components is achieved.

Description

TECHNICAL FIELD

[0001] The present application generally relates to the field of intelligent prefabrication construction technology of railway box girder, and particularly relates to an intelligent prefabrication construction method of railway box girder. BACKGROUND

[0002] Box girder prefabrication is a core technology of box girder production in a prefabricated girder yard based on the concepts of industrialization, standardization and intelligentization, and is a key link in the construction of fabricated bridges. The core is to transfer the traditional on-site pouring process of box girder to a controllable girder yard environment, to realize high-quality production of box girder through precision machining and process operation, and then to transport it to the site for installation. It is widely used in engineering fields such as highway, railway and municipal bridges.

[0003] Meanwhile, in the traditional box girder prefabrication, the intelligence and flexibility between various processing or management centers are poor. For example, different types of box girders require independent sets of formworks and molds, so the human and material resources required in the production process of box girders cannot be ignored, and the production cycle will be seriously delayed, affecting normal construction. SUMMARY

[0004] In view of the above defects or deficiencies in the prior art, it is desirable to provide an intelligent prefabrication construction method of railway box girder.

[0005] The present application provides an intelligent prefabrication construction method of railway box girder, comprising: According to the production specification requirements of the girder yard, temporary building construction is carried out to construct a plurality of mutually coordinated processing and management units; the processing and management units are at least divided into: an intelligent production distribution scheduling center, a material transportation and distribution center and a steel bar processing and distribution center; Based on the cooperation of the material transportation and distribution center and the intelligent production distribution scheduling center, corresponding box girder formwork installation is carried out to obtain a first box girder formwork structure; the box girder formwork includes at least two types, and the box girder formwork of the two types can realize type adjustment of the box girder formwork through mutually replaceable side mold chamfer formworks; the material transportation and distribution center is used to respond to the instructions of the intelligent production distribution scheduling center to distribute the corresponding type of side mold chamfer formwork; According to the engineering requirements, the steel bar processing and distribution center is controlled to process the steel bar semi-finished product, and the processed steel bar is transported to the steel bar binding mold for box girder steel bar binding to obtain a bound and formed steel bar framework; the steel bar processing and distribution center is used to process and distribute the processed steel bar; The hoisting equipment is controlled to place the steel bar framework into the first box girder formwork structure, and the steel bar framework and the first box girder formwork structure are subjected to box girder concrete pouring to obtain a poured box girder body; The first box girder formwork structure in the pouring box girder body is removed, and tensioning operation is performed on the pouring box girder body after the first box girder formwork structure is removed, to obtain a final box girder.

[0006] According to the technical scheme provided in the application, the box girder formwork at least comprises a bottom plate formwork, two side formworks and two groups of replaceable side formwork chamfer formworks, each group of the side formwork chamfer formworks comprises two formworks; the two ends of the bottom plate formwork are connected with the two side formworks through different groups of side formwork chamfer formworks, and different models of box girder formworks can be assembled. Based on the cooperation of the material transportation and distribution center and the intelligent production and distribution scheduling center, corresponding box girder formwork installation is performed to obtain a first box girder formwork structure, including: obtaining a target model required by a prefabricated box girder issued by the intelligent production and distribution scheduling center; according to the target model, confirming the group of side formwork chamfer formworks required; controlling the material transportation and distribution center to transport the bottom plate formwork, the two side formworks and the corresponding group of side formwork chamfer formworks to the site for assembly to obtain the first box girder formwork structure.

[0007] According to the technical scheme provided in the application, according to engineering requirements, the steel bar processing and distribution center processes steel bar semi-products, and transports the processed steel bars to a steel bar binding jig for box girder steel bar binding, including: selecting a box girder steel bar binding jig corresponding to the first box girder formwork structure; controlling a steel bar processing unit in the processing management unit to process steel bar semi-products, and transporting the processed steel bars to the steel bar binding jig by the steel bar processing and distribution center for box girder steel bar binding.

[0008] According to the technical scheme provided in the application, the box girder steel bar binding jig comprises a shared binding platform, and the inside side wall of the shared binding platform is provided with a bottom plate steel bar clamp corresponding to two models of box girder formworks respectively; different bottom plate steel bar clamps can be selected to form different box girder steel bar binding jigs for cooperation with different models of the box girder formwork.

[0009] According to the technical scheme provided in the application, the first box girder formwork structure in the pouring box girder body is removed, and tensioning operation is performed on the pouring box girder body after the first box girder formwork structure is removed, including: Starting a hydraulic system matched with the box girder formwork, and removing the first box girder formwork structure by using the hydraulic system; Applying a tensioning force to the pouring box girder body after the first box girder formwork structure is removed, and monitoring the applied tensioning force and the elongation value of the prestressed steel bar in real time by a tensioning device until the tensioning operation is completed.

[0010] According to the technical scheme provided in the application, after obtaining the final box girder, further comprising: controlling the beam moving machine to move the box girder into the beam storage area; monitoring the position, posture and load of the box girder in real time during the movement of the box girder into the beam storage area; judging whether the box girder is normally moved into the beam storage area according to the position, posture and load.

[0011] According to the technical scheme provided in the application, the beam storage area is provided with a curing monitoring system, and the method further comprises: obtaining the curing time length of each box girder in the beam storage area and the environmental parameters of the beam storage area, wherein the environmental parameters at least include temperature and humidity; controlling the spraying time, interval time and spraying frequency of the beam storage area according to the environmental parameters until each box girder in the beam storage area meets the standard curing index.

[0012] According to the technical scheme provided in the application, the method further comprises: carrying out grouting and anchoring for the box girder meeting the standard curing index and storing the box girder.

[0013] In summary, the technical scheme specifically discloses a railway box girder intelligent prefabrication construction method, wherein the method comprises the following steps: carrying out temporary construction according to the production specification requirements of a beam field to construct a plurality of mutually coordinated processing management units; the processing management units are at least divided into an intelligent production distribution scheduling center, a material transportation distribution center and a steel bar processing distribution center; corresponding box girder formworks are installed based on the cooperation of the material transportation distribution center and the intelligent production distribution scheduling center to obtain a first box girder formwork structure; the box girder formworks at least include two types, and the box girder formworks of the two types can realize type adjustment of the box girder formworks through mutually replaceable side mold chamfer formworks; the material transportation distribution center is used to respond to the instructions of the intelligent production distribution scheduling center to distribute the side mold chamfer formworks of the corresponding types; the steel bar processing distribution center is controlled to process steel bar semi-finished products according to engineering requirements, and the processed steel bars are transported to a steel bar binding jig to carry out box girder steel bar binding to obtain a bound and shaped steel bar framework; the steel bar processing distribution center is used to process and distribute the processed steel bars; the steel bar framework is placed into the first box girder formwork structure by a hoisting device, and the steel bar framework and the first box girder formwork structure are subjected to box girder concrete pouring to obtain a poured box girder body; the first box girder formwork structure in the poured box girder body is removed, and the poured box girder body after the removal of the first box girder formwork structure is subjected to tensioning operation to obtain a final box girder.

[0014] In the prior art, since the box girder prefabrication goes through many steps from production to maintenance and finally to storage, the problem of poor intelligence and flexibility between the processing or management centers of the box girder prefabrication is highlighted, which seriously affects the production cycle of the box girder prefabrication; in the present application, a plurality of processing and management units that can coordinate with each other are preferentially built, and the model adjustment of the box girder formwork is realized through replaceable side mold chamfer templates for the two box girder formworks commonly used in railways, which reduces the number of templates that need to be produced due to different template models, and finally realizes the integration and intelligent control of a series of construction processes from template installation, steel bar processing and binding, concrete pouring to template removal and tensioning operation under the cooperation of each processing and management unit, effectively improves the construction efficiency, shortens the box girder prefabrication cycle, and saves a large amount of labor input; at the same time, the macro size difference of different models of box girders is mapped and packaged in the interchangeable functional module of the side mold chamfer template, and finally, through two groups of side mold chamfer templates with complementary geometric characteristics, the purpose of globally changing the forming size of the box girder formwork by only replacing the local components of the box girder formwork is achieved. BRIEF DESCRIPTION OF DRAWINGS

[0015] Other features, objects, and advantages of the present application will become more apparent from the following detailed description of non-limiting embodiments made with reference to the accompanying drawings: Figure 1 Figure 1 is a flowchart of a railway box girder intelligent prefabrication construction method.

[0016] Figure 2 Figure 2 is a schematic view of a box girder formwork structure.

[0017] Figure 3 Figure 3 is a schematic view of a box girder steel bar binding jig structure.

[0018] Figure 1 is a flowchart of a railway box girder intelligent prefabrication construction method. DETAILED DESCRIPTION

[0019] The present application will be further described in detail below with reference to the accompanying drawings and embodiments. It can be understood that the specific embodiments described herein are only used to explain the related application, and not to limit the application. In addition, it should be noted that only the parts related to the application are shown in the drawings for ease of description.

[0020] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict. The present application will be described in detail below with reference to the accompanying drawings and embodiments.

[0021] Embodiment 1 In order to make the technical solutions of the embodiments of the present application clearer and easier to understand, the application background of the embodiments of the present application is introduced as follows.

[0022] With the implementation of the new infrastructure construction plan, railway engineering construction is facing the dual challenges of scale expansion and quality upgrading. As the core component of railway bridge, the efficiency, precision and environmental protection level of box girder prefabrication directly restrict the realization of the overall progress and sustainable development goals of the project.

[0023] Box girder prefabrication is a key link in bridge construction, and its technology has evolved from early manual dominance to a mature mode dominated by mechanization and automation, achieving the improvement of production efficiency and quality stability. However, with the increasing requirements of engineering construction on efficiency, cost and flexibility, the existing mode still faces new challenges: (1) The flexibility of the mold and mold system is insufficient, and multiple independent templates often need to be configured to adapt to box girders of different sizes, resulting in large resource occupation and low switching efficiency; (2) The coordination between various production units (such as steel bar processing, template assembly, and concrete curing) is weak, affecting the continuity of the overall operation flow; (3) The precision and efficiency of complex steel bar binding still rely on manual experience to a certain extent. Therefore, on the basis of existing mechanization, how to realize flexible configuration and efficient coordination of production resources through intelligent upgrading has become a problem to be solved in the field.

[0024] Therefore, in order to improve the overall prefabrication level of the box girder, the present application proposes an intelligent prefabrication construction method for railway box girders, which comprises: according to the production specification requirements of the beam field, carrying out temporary building construction, and constructing a plurality of mutually coordinated processing management units; the processing management unit is at least divided into: an intelligent production distribution scheduling center, a material transportation and distribution center, and a steel bar processing and distribution center; based on the cooperation of the material transportation and distribution center and the intelligent production distribution scheduling center, the corresponding box girder template installation is carried out, and a first box girder template structure is obtained; the box girder template at least includes two types, and the box girder templates of the two types can realize the adjustment of the type of the box girder template through the mutually replaceable side mold chamfer template; the material transportation and distribution center is used to respond to the instructions of the intelligent production distribution scheduling center to distribute the side mold chamfer template of the corresponding type; according to the engineering requirements, the steel bar processing and distribution center is controlled to process the steel bar semi-finished product, and the processed steel bar is transported to the steel bar binding mold for steel bar binding of the box girder, and a bound and formed steel bar framework is obtained; the steel bar processing and distribution center is used for processing and distributing the processed steel bar; the hoisting equipment is controlled to place the steel bar framework into the first box girder template structure, and the steel bar framework and the first box girder template structure are subjected to box girder concrete pouring, and a poured box girder body is obtained; the first box girder template structure in the poured box girder body is removed, and the poured box girder body after the removal of the first box girder template structure is subjected to tensioning operation, and a final box girder is obtained.

[0025] As can be seen, this application constructs temporary buildings according to the requirements of beam yard production specifications, and establishes multiple coordinated processing management units (intelligent production and distribution scheduling center, material transportation and distribution center, and steel bar processing and distribution center), which can improve construction efficiency and facilitate management and scheduling. The box girder formwork includes at least two models, and the model of the box girder formwork can be adjusted by replacing the side formwork and chamfered formwork, which reduces the number of formwork required due to different formwork models, reduces the formwork purchase cost and storage space requirements, and also facilitates the rapid switching of box girder formwork models according to actual project needs during construction, thereby improving construction efficiency. Finally, through the cooperation of various processing management units, this application realizes the integrated and intelligent control of a series of construction processes from formwork installation, steel bar processing and binding, concrete pouring to formwork removal and tensioning operations, which reduces waiting time and manpower input during construction, helps to ensure the stability of construction quality, improves construction efficiency, and effectively shortens the box girder prefabrication cycle.

[0026] To make the technical solution of this application clearer and easier to understand, the memory optimization method of the memory management large model provided in the embodiments of this application will be described below with reference to the accompanying drawings. Figure 1 , Figure 2 As shown, this figure is a flowchart of the intelligent prefabrication construction method for railway box girders provided in an embodiment of this application. The executing entity of this method can be a digital dispatch and command center, and the method includes: Please refer to Figure 1 The flowchart shown in this embodiment illustrates an intelligent prefabrication construction method for railway box girders, including: S100. In accordance with the production specifications of the beam yard, temporary construction is carried out to build multiple mutually coordinated processing management units; the processing management units are at least divided into: an intelligent production and distribution scheduling center, a material transportation and distribution center, and a steel bar processing and distribution center; According to the production specifications of the beam yard, the processing management unit here follows the "7+1+1" model, which means that its types are: management center, testing center, intelligent production and distribution scheduling center, intelligent steel bar processing and distribution center, material transportation and distribution center, box girder prefabrication center, concrete supply center, industrial worker community, and industrial worker training base, thus building a smart beam yard that integrates training, production, management and living. Among them, (1) Management Center: adopts two-layer light steel structure, which is the management and production integrated office area. The office area includes functional department offices, archives room, conference room and activity room, etc.; (2) Detection Center: adjacent to the management center, adopts two-layer light steel structure, responsible for concrete, steel bar, prefabricated component inspection; (3) Steel bar processing and distribution center: adopts steel structure workshop structure. The center includes raw material storage area, semi-finished product and finished product storage area. In addition, the steel bar processing and distribution center also includes: intelligent steel bar bending center, four-axis intelligent steel bar bending center, intelligent steel bar hydraulic shearing production line, intelligent box girder positioning net welding production line, remote control electric flatbed transport vehicle, etc., which can realize automatic and few-person steel bar processing; (4) Intelligent production and distribution scheduling center: through BIM and GIS three-dimensional scene, visual management of the beam field is realized, and the beam production scene is restored. Through multi-business data full integration, management map is realized. In the beam command center, project production site details and various production data of the beam field can be viewed through the digital large screen, which assists the management personnel to make intelligent decisions; (5) Material transportation and distribution center: under the command of the intelligent production and distribution scheduling center, it is responsible for delivering the correct template components to the correct work site (box girder prefabrication center) at a certain time and in a certain quantity.

[0027] S200, based on the cooperation of the material transportation and distribution center and the intelligent production and distribution scheduling center, corresponding box girder template installation is carried out, and a first box girder template structure is obtained; the box girder template includes at least two types, and the box girder templates of the two types can realize type adjustment of the box girder template through mutually replaceable side mold chamfer templates; the material transportation and distribution center is used to respond to the instruction of the intelligent production and distribution scheduling center to distribute the side mold chamfer templates of the corresponding type; In the construction of high-speed railway bridges, 32-meter standard span box girders are the mainstream (accounting for more than 80%), and 24-meter and 20-meter girders are used as supplementary spans, mainly bearing the functions of topography adaptability adjustment, special structure demand, and engineering economy optimization; therefore, in the embodiments of the present application, the two types of box girder templates included in the box girder template are generally templates of 32-meter box girders and 20-meter box girders.

[0028] Specifically, the two types of box girder templates correspond to the following two box girders respectively: Through bridge (2023) 2322A-II-a (32-meter box girder, beam height 3.032 meters, bottom plate width 5.4m); Through bridge (2023) 2322A-IV (20-meter box girder, beam height 2.432 meters, bottom plate width 5.7m); But due to the structural differences between the two box girder, the traditional central standard section increase and decrease scheme can not be realized because the height difference between the two types of beams is 0.6 meters, so in the embodiment of the application, the side mold chamfer template which can be replaced with each other is used for the two types of box girder formwork to overcome the problem that the two types of box girder formwork cannot be used universally.

[0029] Further, the box girder formwork at least comprises a bottom plate formwork 1, two side mold formworks 2 and two groups of side mold chamfer formworks 3 which can be replaced with each other, each group of side mold chamfer formworks comprises two formworks; the two ends of the bottom plate formwork are connected with the two side mold formworks through different groups of side mold chamfer formworks, and different types of box girder formworks can be assembled; Specifically, the key to realize the universality of the two types of formworks lies in the two groups of side mold chamfer formworks 3, which are designed according to the requirements of the box girder. Figure 2 As shown in the middle, each group of side mold chamfer formworks 3 is a low-high round corner mold 31 and a general-high round corner mold 32 designed according to the requirements of the box girder; wherein the low-high round corner mold 31 can shorten the length of the side mold formwork in the connection direction, increase the length of the bottom plate formwork in the connection direction, realize the widening of the bottom mold after the formwork is assembled, and lower the side mold; the general-high round corner mold 32 can increase the length of the side mold formwork in the connection direction, shorten the length of the bottom plate formwork in the connection direction, realize the shortening of the bottom mold after the formwork is assembled, and increase the height of the side mold; in this way, using different groups of side mold chamfer formworks 3 can obtain two formworks with different bottom mold lengths and side mold heights, which can be connected to form a 32-meter box girder and a 20-meter box girder; specifically, the general-high round corner mold form of the side mold chamfer formwork corresponds to the 32-meter box girder, and the low-high round corner mold form of the side mold chamfer formwork corresponds to the 20-meter box girder; this design enhances the universality and flexibility of the formwork, reduces the number of formworks needed due to different types of formworks, reduces the cost of purchasing formworks and the demand for storage space, and also facilitates the quick switching of formwork types during construction according to actual engineering requirements, improving construction efficiency.

[0030] Based on the cooperation of the material transportation and distribution center and the intelligent production and distribution scheduling center, the corresponding box girder formwork installation is carried out to obtain the first box girder formwork structure: obtaining the target type required by the prefabricated box girder issued by the intelligent production and distribution scheduling center; according to the target type, confirming the group of side mold chamfer formworks required; controlling the material transportation and distribution center to transport the bottom plate formwork, two side mold formworks and the corresponding group of side mold chamfer formworks to the site for assembly to obtain the first box girder formwork structure.

[0031] Since the box girder formwork mentioned above has two models, the installation of the corresponding box girder formwork requires the cooperation of the intelligent production and distribution scheduling center, material transportation and distribution center, and box girder prefabrication center within the processing management unit. After determining the target model required for this prefabrication of the box girder, the intelligent production and distribution scheduling center issues a scheduling instruction (which includes information such as the required module model and quantity, transportation time, and transportation location). This allows the material transportation and distribution center to transport the corresponding side formwork chamfering template 3, bottom plate template 1, and two side formwork templates 2 to the box girder prefabrication center for on-site assembly according to the specific scheduling instruction. Specifically, the bottom plate template 1, side formwork chamfering module 3, and side formwork templates 2 of the box girder are fixed together by bolts. After the template assembly is completed, the camber value of the template can be adjusted according to the drawings. At the same time, an intelligent attached vibrator is installed on the template. Through the intelligent system control of the box girder prefabrication center, the attached vibrator has a higher level of automation and precise control capability.

[0032] It should be noted that the side formwork chamfering template 3, the base plate module 1, and the two side formwork templates 2 require precision control during factory manufacturing (for example, all splicing surfaces of the templates must be milled to ensure the flatness of the joint surfaces); and a pre-assembly inspection will be carried out after production, using precision measuring tools to verify the joint gaps and overall outline dimensions to ensure that the on-site assembly can achieve the precision requirements of seamless connection before being put into use, thereby ensuring that there will be no grout leakage after the side formwork chamfering template 3, the base plate module 1, and the two side formwork templates 2 are spliced ​​together during use; in addition, high-strength bolts selected based on mechanical calculations and construction practice will be used for bolt connections, which have sufficient tensile and shear resistance to ensure that there is no displacement or deformation during concrete pouring.

[0033] S300. According to the project requirements, the steel bar processing and distribution center processes the semi-finished steel bars and transports the processed steel bars to the steel bar binding jig for binding the box girder steel bars to obtain the bound steel bar skeleton; the steel bar processing and distribution center is used to process and distribute the processed steel bars. Specifically, the semi-finished steel bars for the box girder are processed in the intelligent steel bar processing and distribution center. When the steel bars are tied, the remote-controlled electric flatbed transport vehicle of the steel bar processing and distribution center transports the processed steel bars from the semi-finished product storage area to the steel bar tying jig for tying the box girder steel bars.

[0034] According to the engineering requirements, the steel bar processing and distribution center processes the steel bar semi-finished product, and transports the processed steel bar to the steel bar binding mold, and the process of box girder steel bar binding includes: selecting a box girder steel bar binding mold 4 corresponding to the first box girder formwork structure; controlling the steel bar processing and distribution center to process the steel bar semi-finished product, and transporting the processed steel bar to the box girder steel bar binding mold 4 to perform box girder steel bar binding.

[0035] The box girder steel bar binding mold 4 includes a shared binding platform 5, and the inside side wall of the shared binding platform is provided with a bottom plate steel bar clamp 6 corresponding to two types of box girder forms respectively; selecting different bottom plate steel bar clamps 6 can form different box girder steel bar binding molds for cooperation with different types of box girder forms.

[0036] Specifically, the mold used for box girder steel bar binding is similar to the modification of box girder forms, and for 20m and 32m two types of box girder steel bars, the traditional central standard section increasing and decreasing scheme cannot realize the universality of the steel bar binding mold due to the height difference of 0.6m between the two types of beams, and the application innovatively adopts a box girder steel bar shared binding platform 5, the core idea of which is to arrange a raised platform on the 32m box girder binding mold, and place a 20m bottom plate steel bar clamp 61 on the upper part of the raised platform and a 32m bottom plate steel bar clamp 62 on the lower part, so as to complete the function of switching different types of beam steel bar binding molds by placing different bottom plate steel bar clamps 6, which enhances the universality and flexibility of the mold, facilitates quick switching of the mold type during construction according to actual engineering requirements, and improves the construction efficiency.

[0037] In actual use, due to the 150 types of box girder steel bars, the large number of steel bars, the complex processing, and the problem of conflict between steel bars and embedded parts, the number and position of the conflicting steel bars in the steel bar installation are found by using BIM modeling as a method in the early stage, and according to a large number of engineering practices on site, adjustment and installation instructions for conflicting steel bars and gradually changing steel bars are prepared, and a project prefabricated box girder steel bar standardization work atlas is formed. Under the guidance of the prefabricated box girder steel bar standardization work atlas, the box girder steel bar binding is performed by the six-step method of steel bar binding, and the six-step method of steel bar binding is as follows: The first step is to bind U-shaped steel bars, longitudinal steel bars at the bottom layer of the bottom plate, and positioning mesh; the second step is to bind the end steel bars of the bottom plate, the top layer steel bars of the bottom plate, and the lower chamfer of the bottom plate, the hook steel bars of the bottom plate, and the strengthening steel bars in the shape of a well; the third step is to bind the web steel bars, the hook steel bars of the web, and the spiral steel bars of the ventilation hole; the fourth step is to bind the horizontal steel bars at the bottom layer of the top plate, the longitudinal steel bars, and the end steel bars; the fifth step is to bind the top layer steel bars of the top plate, the longitudinal steel bars, the hook steel bars of the top plate, and the strengthening steel bars in the shape of a well; and the sixth step is to bind the steel bars of the A wall, the B wall, and the protective wall, the steel bars of the water retaining wall, the embedded sleeve, the grounding steel bars, the contact net, and the lower anchoring line. The process is beneficial to improving the on-site operation efficiency and the steel bar binding quality through mold binding, standardized operation, and programmed inspection.

[0038] Further, the processed steel bars can be guided by the prefabricated box girder steel bar standardized operation album when being transported to the box girder steel bar binding mold 4 for box girder steel bar binding. Here, the prefabricated box girder steel bar standardized operation album is briefly described. Taking the N6 steel bar adjustment description recorded in the album as an example, it is assumed that the original design condition is that the N6 steel bars are door-shaped steel bars at the beam end, with 4 steel bars at each corner, and a total of 16 steel bars. However, it is found by the technical personnel in the BIM modeling that the end of the horizontal section of the first two N6 steel bars conflicts with the N2a anchor hole, and the hook at the end conflicts with the N2c anchor hole, and the last two N6 steel bars are not arranged according to the arc chamfer of the manhole. After the technical personnel make adjustments according to experience and the assistance of BIM modeling, it is finally confirmed that the two 135° hooks at the end of the first two N6 steel bars are adjusted to be 90°, and the lengths of the flat sections at the upper and lower layers of the bottom plate are adjusted to be 1322 mm and 1842 mm respectively. The lengths of the flat sections at the upper and lower layers of the bottom plate of the last two N6 steel bars are adjusted to be 1402 mm and 1922 mm respectively. It is also confirmed that such adjustment needs to be performed on all 16 steel bars. Finally, these adjustment conditions and descriptions are edited and recorded to form a corresponding prefabricated box girder steel bar standardized operation album, which is used for actual box girder steel bar binding. When the corresponding conflict problem occurs or the same binding operation is performed, the corresponding steel bars can be directly adjusted according to the adjustment description in the album.

[0039] In addition, in the embodiment of the present application, in order to speed up the construction progress, an automatic telescopic rain shed is arranged in the steel bar binding area. When the gantry crane approaches the rain shed, the rain shed is automatically retracted through infrared induction. The telescopic shed is driven by a walking motor to realize automatic telescoping and moving to the other side of the binding area.

[0040] S400, control the hoisting equipment to place the steel bar framework into the first box girder formwork structure, and perform box girder concrete pouring on the steel bar framework and the first box girder formwork structure to obtain a poured box girder body; According to the construction process, the reinforced skeleton after binding needs to be placed into the first box girder formwork structure by hoisting equipment for the step of box girder concrete pouring. In the actual construction process, a concrete distributing machine needs to be used. Due to the large amount of beam body concrete and the use of high-performance concrete, in order to shorten the pouring time, two HG19AG type concrete distributing machines are used for continuous pouring and one-time forming to ensure that the beam body concrete is poured within 6 hours.

[0041] Further, the concrete distributing machine adopts a round pipe tower body, a horizontal variable amplitude arm rod and wireless remote control operation, can realize the combined use of one distributing machine and multiple foundations, is suitable for large and medium-sized box girder prefabrication, has a whole machine height of 6.8 m, a self weight of 8.5 t, a rotation range of 400° and a maximum distributing radius of 19 m, and can directly use the gantry crane of the prefabrication yard to realize the rapid conversion of the distributing machine among multiple foundations.

[0042] S500, the first box girder formwork structure in the pouring box girder body is removed, and tensioning operation is performed on the pouring box girder body after the first box girder formwork structure is removed, to obtain a final box girder.

[0043] Specifically, the above process is specifically: starting the hydraulic system matched with the box girder formwork, removing the first box girder formwork structure by using the hydraulic system; applying a tensioning force to the pouring box girder body after the first box girder formwork structure is removed, and monitoring the applied tensioning force and the elongation value of the prestressed steel bar in real time by the tensioning equipment until the tensioning operation is completed.

[0044] Wherein, the box girder demolding and formwork removal can be easily realized through the hydraulic system of the formwork, the target is to separate the formwork from the solidified box girder concrete surface without damage, and the step-by-step pushing action is completed relying on the hydraulic system; after starting the hydraulic system, the small hydraulic cylinders at the corner parts of the formwork (such as the oil cylinders at the corner parts of the box girder flange plate and web plate) can be preferentially controlled to act, a uniform pushing force is applied to the corner parts of the formwork, a small gap (usually 1-2 mm) is first generated between the corner parts of the formwork and the concrete surface, the adsorption stress generated by long-term adhesion is released, the pushing force is monitored in real time by the pressure sensor of the hydraulic system in the process, if the pressure suddenly rises (indicating that there is local adhesion), the pushing is immediately stopped, and manual inspection is performed to check whether there is concrete adhesion, to avoid damage to the corner parts caused by forced pushing; after the corner parts are pre-loosened, the hydraulic drive system of the main part of the formwork (such as the large pushing oil cylinder of the side formwork 2 and the bottom plate formwork 1) can be switched, and the operation is performed according to the principle of symmetry and synchronization, when the separation distance between the side formwork 2 and the concrete surface reaches 50-100 mm (which can be observed through the scale on the formwork), the web plate pushing can be paused, and the hydraulic oil cylinder of the bottom plate formwork 1 is started to slowly push the bottom plate formwork 1, until the bottom plate formwork 1 completely separates from the bottom of the box girder, to complete the removal of the first box girder formwork structure in the pouring box girder body.

[0045] When the tensioning device applies tension to the cast box girder body after the first box girder formwork structure is removed, the tensioning device needs to use a high-precision pressure sensor to directly measure the tension, a digital displacement sensor to measure the elongation value, a high-performance ultrahigh-pressure hydraulic system as a power load, an industrial programmable controller (PLC) to automatically collect data and control system operation, and a computer management system to perform auxiliary functions such as tension data management, oil temperature control, oil pressure protection, and intelligent diagnosis, together forming an automatic bridge prestressed tensioning device; the tensioning device can realize full-process self-balancing tensioning, that is, through presetting tensioning process parameters by a computer, real-time calibration of tension and elongation values during the entire tensioning process, automatic collection and analysis of process data, real-time reporting of tensioning results, and data transmission and remote control with an upper-layer information management center.

[0046] The intelligent tensioning control is accurate, supports parameter pre-setting and one-key tensioning start, automatically completes the entire tensioning process, automatically balances and synchronously tensions, automatically controls pressure compensation, controls the index value within a range of 1% above and below the value, automatically calculates and prints a record table, and remotely transmits tensioning results and the tensioning process for reference.

[0047] In some embodiments, after obtaining the final box girder, the method further includes: Step A1, controlling the beam-moving machine to move the box girder into the beam storage area; Step A2, monitoring the position, posture, and load of the box girder in real time during the movement of the box girder into the beam storage area; Step A3, judging whether the box girder is normally moved into the beam storage area according to the position, posture, and load.

[0048] After the preliminary tensioning of the box girder is completed, the box girder needs to be transferred to a dedicated beam storage area (for temporary storage, maintenance, or waiting for subsequent beam transport vehicles to transport to the beam erecting site). This process can be achieved by moving the box girder into the beam storage area using a 900T automatic beam-moving machine. The 900T beam-moving machine mainly consists of a main beam, a support leg, a tire-type walking trolley, a hydraulic transmission system, a hydraulic braking system, a steering system, a power module, an electrical system, a micro-electric control system, an operation room, a lifting system, a lifting and supporting hydraulic system, an amplitude changing system, safety devices, and the like. It is suitable for lifting, transferring, and loading onto beam transport vehicles for 32m, 24m, and 20m whole-hole double-line box girders in domestic 350km / h and 250km / h railway passenger dedicated line precast yards. Sensors and visual recognition systems are arranged to optimize the operation process through artificial intelligence algorithms, improving efficiency and accuracy. Sensors and cameras are used to monitor the equipment state and working environment in real time, allowing real-time monitoring of the position, posture, and load of the beam body, precise beam lifting operations, and safe lifting. The 900T beam-moving machine can also assist in the installation of the bridge erecting machine and the beam transport vehicle and the hoisting of the reinforcement framework and formwork in the precast yard.

[0049] In some embodiments, the storage beam area is provided with a curing monitoring system, and the method further comprises: Step C1, obtaining the curing time of each box girder in the storage beam area and the environmental parameters of the storage beam area, the environmental parameters at least including temperature, humidity; Step C2, according to the environmental parameters, controlling the spraying time, interval time and spraying frequency of the storage beam area until each box girder in the storage beam area meets the standard curing index.

[0050] Regarding the curing link of beam yard components (such as precast beams, plates and other concrete components), the curing time refers to the total time of continuously maintaining the moisture curing of the concrete components after the pouring is completed under the conditions of meeting the standard temperature and humidity, and the setting and execution of the index directly determine the final performance of the components. At the same time, for different box girders, the curing time is not a fixed value, which needs to be determined according to the component type, concrete strength grade, construction environment (such as season, temperature) and design requirements, so as to ensure that the service life and component strength of the box girder meet the requirements.

[0051] The storage beam area here is provided with a curing monitoring system, which adopts automatic curing equipment and is mainly composed of HMI touch screen, WIFI, PLC computer, frequency converter, motor, water pump, electromagnetic valve and other components, is connected to the platform intelligent curing monitoring system, and monitors, analyzes and warns the key parameters such as curing time, temperature and humidity. For example, when the temperature or humidity does not meet the curing requirement standard, the spraying will be automatically controlled to start, and the spraying time, interval time and spraying frequency can be adjusted according to the current environmental temperature and humidity to meet the standard curing index. In addition, the system can automatically generate component curing account records, analyze component curing indexes and ensure component quality.

[0052] In some embodiments, the method further comprises: performing pipe grouting and anchoring sealing for the box girder meeting the standard curing index.

[0053] Regarding the pipe grouting and anchoring sealing operation, it can be performed within 48 hours after the final tensioning of the steel strand bundle of the box girder is completed. In the embodiments of the present application, the prestressed pipe grouting adopts vacuum-assisted grouting process, and the specific process flow is as follows: Cut off exposed steel strand - remove debris and water from duct - seal anchor with non-shrink cement mortar - clean grout holes on anchor bed plate - determine vacuum and grout ends, install lead pipe, ball valve and joint - mix cement paste - start vacuum pump (vacuum degree reaches -0.06 to -0.08 MPa and remains stable) - start grouting pump, start grouting (vacuum pump continues to work) - when the transparent mesh tube at the vacuum end has grout passing through, close the valve at the front of the air filter - open the exhaust valve later until the cement paste flows smoothly - when the grout consistency is equivalent to the grout poured in, close all valves at the vacuum end - the grouting pump is held at 0.50 to 0.60 MPa for 3 minutes - close the grouting pump and the grouting end valve - remove the external pipeline, accessories, clean the air filter and valves - clean all equipment contaminated with cement paste - remove and clean the ball valves installed at the grouting end and the grout end after 5 hours.

[0054] Based on the above operation process, the prestressed pipe intelligent grouting integrated vehicle is used for the prestress pipe grouting and anchoring operation. The vehicle is equipped with an automatic grouting system, which mainly includes four hardware parts of grouting, vacuum pump, grouting, auxiliary device, and a control system and a data system. The grouting device has the functions of automatic feeding, weighing and batching, high-speed grouting, and low-speed grouting. The auxiliary part can realize self-diagnosis, self-protection, alarm and early warning, self-cleaning, power-off protection, and continuous working, and environmental protection dust removal functions. The construction of the data system realizes the information management of automatic grouting, which is a modern management mode with efficient database as the back end and visual charts as the display, including data storage, data viewing, data analysis and statistics, chart display, data transmission and the like. The control system realizes the overall control and collaborative work of the automatic grouting system through the PLC programmable control module and program, realizes the on-site man-machine interaction and remote management, and is the core and center of realizing the automation, informatization and networking of grouting construction operation and management.

[0055] Among them, the end sealing concrete adopts non-shrinkage concrete, and the compressive strength is not less than the design requirement. Before sealing, the anchor hole around is chiseled by the anchor hole chiseling and cutting all-in-one machine to increase the bonding force of the concrete. After the sealing and the anchor hole chiseling and cutting all-in-one machine are completed, the end sealing steel bars are bound, and the C50 compensation shrinkage concrete is filled and tamped. The filling surface is flush with the end surface. After the sealing concrete is initially cured, a water energy film is used for curing. After the curing of the end sealing concrete is completed, polyurethane waterproof paint is applied for waterproof treatment. It should be noted that the concrete vibration can use the inserted high-frequency vibration rod and the attached flat plate vibrator. The concrete vibration should not collide with the formwork, steel bars and embedded iron parts. The concrete vibration should be carried out according to the pre-specified process route and mode, and should be timely and uniformly vibrated and compacted during the concrete pouring process. The vibration time of each point is based on the surface spattering or large air bubbles, and generally does not exceed 30 seconds to avoid over-vibration.

[0056] Regarding the storage operation of the box girder, in the embodiment of the present application, the box girder is stored in double layers; (1) Lower layer of stored girders: when hoisting the girders for storage, first, the top surfaces of the four supporting abutments of the stored girder pedestal are measured horizontally, and if the height difference exceeds the standard, different thickness steel plates are used to ensure that the four supporting points are in the same plane. The support adopts a 600*800*600mm reinforced concrete support plus a 500*800*70mm rubber support, and the bearing capacity meets the requirement of 500t.

[0057] (2) Upper layer of stored girders: when double layers of girders are stored, both the upper and lower box girders are supported by four points, and the supporting points are symmetrically arranged according to the center line of the box girder. The support adopts a 500*800*50mm rubber support, wherein the center of the supporting point of the lower box girder is 55±50mm away from the end of the beam in the longitudinal direction, and the transverse distance should be 5200mm, and the supporting area is 500*800mm. When the upper layer of girders is stored, the distance from the center of the supporting point of the box girder to the end of the beam in the longitudinal direction is consistent with that of the lower layer, and the transverse distance is 5200mm, and the supporting area is the same as that of the lower layer of stored girders. At the same time, attention should be paid to observing the flatness of the supporting points in time during construction to ensure that the unevenness of the supporting points of the upper and lower layers of girders is not greater than 2mm. It should be noted that double layers of girders are only allowed to be stacked according to the above requirements, and girders of different spans are prohibited from being stacked with each other.

[0058] In order to integrate the information of the box girder from production, storage, transportation to installation and operation and maintenance, realize the convenience of information tracing and the visualization of progress control, and provide a dedicated identification two-dimensional code identification for different box girders in the embodiment of the present application, so as to realize the information tracing of the whole life cycle of the box girder. Each box girder corresponds to a dedicated two-dimensional code, and the basic information of the beam piece can be quickly obtained through the two-dimensional code, reducing the amount of manual information input. The on-site progress management personnel only need to take pictures to record the process progress of the beam piece, and the component progress information can be updated, and the detailed visual progress chart of the bridge can be viewed, which provides help for the preparation of the weekly plan from various aspects such as vision and data display.

[0059] The above description is only a preferred embodiment of the present application and a description of the technical principles applied. Those skilled in the art should understand that the scope of the application involved in the present application is not limited to the technical solutions formed by the specific combination of the above technical features, and should also cover other technical solutions formed by any combination of the above technical features or their equivalent features without departing from the inventive concept. For example, the above features are replaced with the technical features disclosed in the present application (but not limited to) having similar functions to form a technical solution.

Claims

1. A railway box girder intelligent prefabrication construction method, characterized in that, The application relates to a prefabricated box girder production system and a production method thereof. According to the production specification requirements of a beam field, temporary building construction is carried out, and a plurality of mutually coordinated and matched processing management units are constructed; The processing management units are at least divided into an intelligent production and distribution scheduling center, a material transportation and distribution center and a steel bar processing and distribution center; Based on the cooperation of the material transportation and distribution center and the intelligent production and distribution scheduling center, corresponding box girder template installation is carried out, and a first box girder template structure is obtained; the box girder template at least includes two types, and the box girder templates of the two types can realize type adjustment of the box girder template through mutually replaceable side mold chamfer templates; the material transportation and distribution center is used for responding to the instruction of the intelligent production and distribution scheduling center to distribute the side mold chamfer templates of the corresponding type; According to engineering requirements, the steel bar processing and distribution center is controlled to process steel bar semi-products, and the processed steel bars are transported to a steel bar binding mold to carry out box girder steel bar binding, and a bound and formed steel bar framework is obtained; the steel bar processing and distribution center is used for processing and distributing the processed steel bars; The steel bar framework is placed into the first box girder template structure by a hoisting device, and the steel bar framework and the first box girder template structure are subjected to box girder concrete pouring, and a poured box girder body is obtained; The first box girder template structure in the poured box girder body is removed, and the poured box girder body after the first box girder template structure is removed is subjected to tensioning operation, and a final box girder is obtained.

2. The intelligent prefabrication construction method of railway box girder according to claim 1, characterized in that, The box girder template at least includes a bottom plate template, two side mold templates and two groups of mutually replaceable side mold chamfer templates, each group of the side mold chamfer templates includes two templates; the two ends of the bottom plate template are connected with the two side mold templates through different groups of side mold chamfer templates, and different types of box girder templates can be assembled; Based on the cooperation of the material transportation and distribution center and the intelligent production and distribution scheduling center, corresponding box girder template installation is carried out, and a first box girder template structure is obtained, including: The target type required by the prefabricated box girder issued by the intelligent production and distribution scheduling center is acquired; according to the target type, the group of the required side mold chamfer template is confirmed; the material transportation and distribution center is controlled to transport the bottom plate template, the two side mold templates and the side mold chamfer template of the corresponding group to the site for assembly, and the first box girder template structure is obtained.

3. The intelligent prefabrication construction method of railway box girder according to claim 1, characterized in that, According to engineering requirements, the steel bar processing and distribution center is controlled to process steel bar semi-products, and the processed steel bars are transported to a steel bar binding mold to carry out box girder steel bar binding, including: selecting a box girder steel bar binding mold corresponding to the first box girder template structure; the steel bar processing unit of the steel bar processing and distribution center is controlled to process steel bar semi-products, and the processed steel bars are transported to the box girder steel bar binding mold to carry out box girder steel bar binding.

4. The intelligent prefabrication construction method of railway box girder according to claim 3, characterized in that, The box girder steel bar binding mold includes a shared binding platform, and the inner side wall of the shared binding platform is provided with bottom plate steel bar fixtures corresponding to the box girder templates of the two types respectively; different bottom plate steel bar fixtures can form different box girder steel bar binding molds for matching the box girder templates of different types.

5. The intelligent prefabrication construction method of railway box girder according to claim 1, characterized in that, The first box girder formwork structure in the pouring box girder body is demolished, and a tensioning operation is performed on the pouring box girder body after the first box girder formwork structure is demolished, comprising: Starting a hydraulic system matched with the box girder formwork, and demolishing the first box girder formwork structure by using the hydraulic system; Applying a tensioning force to the pouring box girder body after the first box girder formwork structure is demolished, and monitoring the applied tensioning force and the elongation value of the prestressed steel bars in real time by the tensioning equipment until the tensioning operation is completed.

6. The intelligent prefabrication construction method of railway box girder according to claim 1, characterized in that, After obtaining the final box girder, further comprising: Controlling the beam moving machine to move the box girder into the beam storage area; Monitoring the position, posture and load of the box girder in real time during the process of moving the box girder into the beam storage area; According to the position, posture and load, judging whether the box girder is normally moved into the beam storage area.

7. The intelligent prefabrication construction method of railway box girder according to claim 6, characterized in that, The beam storage area is provided with a curing monitoring system, and the method further comprises: Obtaining the curing time length of each box girder in the beam storage area and the environmental parameters of the beam storage area, the environmental parameters at least including temperature and humidity; According to the environmental parameters, controlling the spraying time, interval time and spraying times of the beam storage area until each box girder in the beam storage area meets the standard curing index.

8. The intelligent prefabrication construction method of railway box girder according to claim 7, characterized in that, The method further comprises: grouting and anchoring the box girder meeting the standard curing index and storing it.

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