Railway box girder intelligent prefabrication construction method

Abstract

The application discloses a railway box girder intelligent prefabrication construction method, relates to the technical field of railway box girder intelligent prefabrication construction, and comprises the following steps: constructing a plurality of processing management units which are high in intelligent degree and can be coordinated with each other; based on the coordination of the processing management units, corresponding box girder formworks are installed; 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; according to engineering requirements, the processed steel bars are transported to a steel bar binding jig for binding to obtain a bound steel bar framework, and a BIM modeling is used to solve the steel bar conflict problem in the process. The method improves the construction efficiency by means of intelligent means and more effectively shortens the box girder prefabrication period; by setting the mutually replaceable side mold chamfer formworks, the purpose that the forming size of the box girder formwork can be globally changed by only replacing partial 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 manpower 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:

[0006] According to the production specification requirements of the girder yard, temporary construction is carried out, and a plurality of mutually coordinated processing and management units are constructed; 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;

[0007] 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, and a first box girder formwork structure is obtained; 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;

[0008] 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 for box girder steel bar binding, and obtains a bound and formed steel bar framework; the steel bar processing and distribution center is used to process and distribute the processed steel bar;

[0009] The hoisting equipment is controlled to place the steel reinforcement framework into the first box girder formwork structure, and the steel reinforcement framework and the first box girder formwork structure are subjected to box girder concrete pouring to obtain a poured box girder body.

[0010] The first box girder formwork structure in the poured box girder body is removed, and the poured box girder body after the first box girder formwork structure is removed is subjected to tensioning operation to obtain a final box girder.

[0011] 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 types of box girder formworks can be assembled.

[0012] 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 type required by a prefabricated box girder issued by the intelligent production and distribution scheduling center; according to the target type, 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.

[0013] According to the technical scheme provided in the application, according to engineering requirements, the steel reinforcement processing and distribution center is controlled to process steel reinforcement semi-products, and the processed steel reinforcements are transported to a box girder steel reinforcement binding jig for box girder steel reinforcement binding, including: selecting a box girder steel reinforcement binding jig corresponding to the first box girder formwork structure; controlling a steel reinforcement processing unit in the processing management unit to process steel reinforcement semi-products, and transporting the processed steel reinforcements to the steel reinforcement binding jig by the steel reinforcement processing and distribution center for box girder steel reinforcement binding.

[0014] According to the technical scheme provided in the application, the box girder steel reinforcement binding jig comprises a shared binding platform, and the inner side wall of the shared binding platform is provided with a bottom plate steel reinforcement clamp corresponding to two types of box girder formworks respectively; different bottom plate steel reinforcement clamps can be selected to form different box girder steel reinforcement binding jigs for cooperation with different types of box girder formworks.

[0015] According to the technical scheme provided in the application, the first box girder formwork structure in the poured box girder body is removed, and the poured box girder body after the first box girder formwork structure is removed is subjected to tensioning operation, including:

[0016] A hydraulic system matched with the box girder formwork is started, and the first box girder formwork structure is removed by using the hydraulic system;

[0017] The tensioning force is applied to the casted box girder body after the first box girder formwork structure is removed, and the applied tensioning force and the elongation value of the prestressed steel bar are monitored in real time by the tensioning equipment until the tensioning operation is completed.

[0018] According to the technical scheme provided in the application, after the final box girder is obtained, the method further comprises:

[0019] controlling the beam moving machine to move the box girder into the beam storage area;

[0020] In the process of moving the box girder into the beam storage area, the position, posture and load of the box girder are monitored in real time.

[0021] According to the position, posture and load, it is judged whether the box girder is normally moved into the beam storage area.

[0022] According to the technical scheme provided in the application, the beam storage area is provided with a maintenance monitoring system, and the method further comprises:

[0023] obtaining the maintenance 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;

[0024] According to the environmental parameters, the spraying time, interval time and spraying frequency of the beam storage area are controlled until each box girder in the beam storage area meets the standard maintenance index.

[0025] According to the technical scheme provided in the application, the method further comprises: grouting and anchoring the box girder meeting the standard maintenance index and storing it.

[0026] In summary, the technical scheme specifically discloses a railway box girder intelligent prefabrication construction method, wherein the method comprises the following steps: according to the production specification requirements of a beam field, carrying out temporary building construction, and constructing a plurality of processing management units that can coordinate with each other; the processing management unit is at least divided into an intelligent production distribution scheduling center, a material transportation distribution center and a steel bar processing distribution center; based on the cooperation of the material transportation distribution center and the intelligent production distribution scheduling center, corresponding box girder formwork installation is carried out, and a first box girder formwork structure is obtained; the box girder formwork comprises 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 distribution center is used for responding to the instruction of the intelligent production distribution scheduling center to distribute the side mold chamfer formwork of the corresponding type; according to engineering requirements, the steel bar processing distribution center is controlled to process steel bar semi-finished products, and the processed steel bars are transported to a steel bar binding jig for box girder steel bar binding, so that a bound and formed steel bar framework is obtained; the steel bar processing distribution center is used for processing and distributing the processed steel bars; 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, so that a poured box girder body is obtained; 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, so that a final box girder is obtained.

[0027] In the prior art, since the box girder prefabrication experiences many steps from production to curing 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 management units that can coordinate with each other are preferentially built, and type adjustment of the box girder formwork is realized through replaceable side mold chamfer formworks for the two types of box girder formworks commonly used in railways, so that the number of formworks to be produced due to different types of formworks is reduced, and finally, under the cooperation of the processing management units, 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 operation is realized, the construction efficiency is effectively improved, the box girder prefabrication cycle is shortened, and a large amount of labor input is also saved; meanwhile, the macro size difference of different types of box girders is mapped and encapsulated in the interchangeable function module of the side mold chamfer formwork, and finally, through the two groups of side mold chamfer formworks 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 realized. BRIEF DESCRIPTION OF DRAWINGS

[0028] Other characteristics, objects and advantages of the present application will become more apparent from the following detailed description of non-restrictive embodiments, made with reference to the accompanying drawings:

[0029] Figure 1It is a flowchart of a railway box girder intelligent prefabrication construction method.

[0030] Figure 2 It is a box girder formwork structure schematic diagram.

[0031] Figure 3 It is a box girder reinforcement binding jig structure schematic diagram.

[0032] In the figure, the labels are: 1, bottom plate formwork; 2, side mold formwork; 3, side mold chamfer formwork; 31, low-high round corner mold; 32, general high round corner mold; 4, box girder reinforcement binding jig; 5, shared binding platform; 6, bottom plate reinforcement fixture; 61, 20-meter bottom plate reinforcement fixture; 62, 32-meter bottom plate reinforcement fixture. DETAILED DESCRIPTION

[0033] The application will be described in further detail below with reference to the 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.

[0034] 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 drawings and in combination with the embodiments.

[0035] Embodiment 1

[0036] In order to make the technical solutions of the embodiments of the present application more clear and easy to understand, the application background of the embodiments of the present application is introduced below.

[0037] 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 the prefabrication production of box girder directly restrict the realization of the overall progress and sustainable development goals of the project.

[0038] Precast of box girder is a key link in bridge construction. Its technology has evolved from early manual dominance to mature mode dominated by mechanization and automation, achieving the improvement of production efficiency and quality stability. However, with the increasing requirements of efficiency, cost and flexibility of engineering construction, the existing mode still faces new challenges: (1) The flexibility of the mold and jig system is insufficient. Multiple independent templates are often 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 depend on manual experience to some 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 this field.

[0039] Therefore, in order to improve the overall precast level of the box girder, the present application proposes an intelligent precast construction method for railway box girder, which comprises: according to the production specification requirements of the girder 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 type adjustment 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 jig for box girder steel bar binding, and a binding 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 to obtain a poured box girder body; 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 to obtain the final box girder.

[0040] 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.

[0041] 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:

[0042] Please refer to Figure 1 The flowchart shown in this embodiment illustrates an intelligent prefabrication construction method for railway box girders, including:

[0043] 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;

[0044] 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.

[0045] 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 and 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 dispatching 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 dispatching center, it is responsible for delivering correct template components to correct work sites (box girder prefabrication center) at a certain time and in a certain quantity.

[0046] S200, based on the cooperation of the material transportation and distribution center and the intelligent production and distribution dispatching center, corresponding box girder template installation is performed to obtain a first box girder template structure; 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 dispatching center to distribute side mold chamfer templates of corresponding types;

[0047] 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.

[0048] Specifically, the two types of box girder templates correspond to the following two box girders, respectively:

[0049] Bridge (2023) 2322A-II-a (32-meter box girder, beam height 3.032 meters, bottom plate width 5.4m);

[0050] Bridge (2023) 2322A-IV (20-meter box girder, beam height 2.432 meters, bottom plate width 5.7m);

[0051] 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.

[0052] 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;

[0053] 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.

[0054] 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.

[0055] Due to the two types of box girder formwork mentioned in the foregoing, the intelligent production and distribution scheduling center, the material transportation and distribution center and the box girder prefabrication center in the processing management unit need to cooperate with each other when installing the corresponding box girder formwork. After the target type required for the prefabricated box girder is determined, the intelligent production and distribution scheduling center issues a scheduling instruction (which includes information such as the type and quantity of modules required, the transportation time and the transportation location) to enable the material transportation and distribution center to transport the corresponding side mold chamfer formwork 3, the bottom plate formwork 1 and the two side mold formworks 2 to the box girder prefabrication center for on-site assembly. Specifically, the bottom plate formwork 1 of the box girder, the side mold chamfer module 3 and the side mold formwork 2 are fixed by bolt connection, and after the formwork assembly is completed, the formwork reverse arch value can also be adjusted according to the drawing, and at the same time, the intelligent attached vibrator is installed on the formwork, which has higher automation level and precise control ability through the intelligent system control of the box girder prefabrication center.

[0056] It should be noted that the side mold chamfer formwork 3, the bottom plate module 1 and the two side mold formworks 2 need to control the product precision during the manufacturing process in the factory (for example, the splicing surfaces of all the formworks need to be milled to ensure the flatness of the joint surfaces); and after production, pre-assembly inspection will be carried out, and precise measuring tools will be used to verify the joint gap and overall contour size to ensure that the on-site assembly can meet the seamless joint precision requirement before being put into use, so as to ensure that the side mold chamfer formwork 3 and the bottom plate module 1 and the two side mold formworks 2 will not leak during use; in addition, the connection of the bolts will also use high-strength bolts selected based on mechanical calculation and construction practice, which have sufficient tensile and shear capacity, so as to ensure that displacement or deformation does not occur during concrete pouring.

[0057] S300, 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 for box girder steel bar binding to obtain a bound and formed steel bar framework; the steel bar processing and distribution center is used for processing and distributing the processed steel bar;

[0058] Specifically, the box girder steel bar semi-finished product is processed in the intelligent steel bar processing and distribution center, and when the steel bar binding is performed, the processed steel bar is transported from the semi-finished product storage area to the steel bar binding mold by the remote-controlled electric flatbed transport vehicle of the steel bar processing and distribution center for box girder steel bar binding.

[0059] 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 jig, and the process of box girder steel bar binding includes: selecting a box girder steel bar binding jig 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 jig 4 to perform box girder steel bar binding.

[0060] The box girder steel bar binding jig 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 jigs for cooperating with different types of box girder forms.

[0061] Specifically, the jig used for box girder steel bar binding is similar to the modification of the box girder formwork, 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 jig 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 jig, 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 jigs by placing different bottom plate steel bar clamps 6, which enhances the universality and flexibility of the jig, facilitates the quick switching of the jig type during the construction process according to the actual engineering requirements, and improves the construction efficiency.

[0062] 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, in the early stage, the number and position of the conflicting steel bars in the steel bar installation are found by using BIM modeling method, and according to a large number of engineering practices on site, adjustment and installation instructions for the conflicting steel bars and the gradually changing steel bars are prepared, a project prefabricated box girder steel bar standardization operation album is formed, and under the guidance of the prefabricated box girder steel bar standardization operation album, 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:

[0063] The first step is to bind U-shaped steel bars, bottom plate bottom layer longitudinal steel bars, and positioning mesh; the second step is to bind bottom plate end steel bars, bottom plate top layer steel bars, bottom plate lower chamfer, bottom plate pull hook steel bars, and well-shaped reinforcing steel bars; the third step is to bind web steel bars, web pull hook steel bars, and ventilation hole spiral steel bars; the fourth step is to bind top plate bottom layer transverse steel bars, longitudinal steel bars, and end steel bars; the fifth step is to bind top plate top layer steel bars, longitudinal steel bars, top plate pull hook steel bars, and well-shaped reinforcing steel bars; and the sixth step is to bind A and B wall and protective wall steel bars, water retaining wall steel bars, pre-buried sleeves, grounding steel bars, contact net, and lower anchor lines. 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.

[0064] Further, the processed steel bars can be bound under the guidance of 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 bar is a beam end door-shaped steel bar, and there are 4 steel bars at each corner, 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 end hook conflicts with the N2c anchor hole, and the last two N6 steel bars are not set according to the manhole arc chamfer. After the technical personnel make adjustments according to experience and the assistance of BIM modeling, the final adjustment method is determined as follows: the two 135° hooks at the end of the first two N6 steel bars are adjusted to be 90°, and the lengths of the upper and lower flat sections at the bottom plate are adjusted to be 1322 mm and 1842 mm respectively; the lengths of the upper and lower flat sections at 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 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.

[0065] 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.

[0066] 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;

[0067] 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.

[0068] 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 quick conversion of the distributing machine among multiple foundations.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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, to jointly form a bridge prestressed automatic tensioning device. The tensioning device can realize full-process self-powered balanced 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, data transmission with an upper-layer information management center, and remote control.

[0073] The intelligent tensioning control is accurate, supports one-key start tensioning with parameter pre-setting, 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 the tensioning results and the tensioning process for reference.

[0074] In some embodiments, after obtaining the final box girder, the method further includes:

[0075] Step A1, controlling the beam mover to move the box girder into the beam storage area;

[0076] 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;

[0077] Step A3, judging whether the box girder is normally moved into the beam storage area according to the position, posture, and load.

[0078] After the preliminary tensioning of the box girder is completed, the box girder needs to be transferred to a special storage area (for temporary storage, maintenance or waiting for subsequent transfer to the girder erection site), and this process can be achieved by moving the box girder into the storage area by a 900T automatic girder moving machine. The 900T girder moving machine is mainly composed of a main beam, a supporting 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, etc. It is suitable for lifting, transferring and loading the 32m, 24m and 20m whole-hole double-line box girders in the domestic 350km / h and 250km / h railway passenger dedicated line precast yard. Sensors and visual recognition systems are arranged to optimize the operation process through artificial intelligence algorithms, improve efficiency and accuracy, and monitor the equipment state and working environment in real time through sensors and cameras. The position, attitude and load of the girder body can be monitored in real time to realize accurate lifting of the girder body and safe lifting. At the same time, it can assist in the installation of the bridge girder and the girder moving vehicle and the hoisting of the reinforcement framework and the formwork in the precast yard.

[0079] In some embodiments, the storage area is provided with a maintenance monitoring system, and the method further comprises:

[0080] Step C1, obtaining the maintenance duration of each box girder in the storage area and the environmental parameters of the storage area, the environmental parameters at least including temperature, humidity;

[0081] Step C2, according to the environmental parameters, controlling the spraying time, interval time and spraying times of the storage area until each box girder in the storage area meets the standard maintenance index.

[0082] Regarding the maintenance link of the beam field components (such as precast girders, plates and other concrete components), the maintenance duration refers to the total time of maintaining the moisture after the concrete component is poured and completed under the condition of meeting the standard temperature and humidity. The setting and execution of the index directly determine the final performance of the component, and for different box girders, the maintenance duration 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.

[0083] The beam storage area is provided with a maintenance monitoring system, which adopts automatic maintenance 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 maintenance monitoring system, and monitors, analyzes and warns key parameters such as maintenance time, temperature and humidity. For example, when the temperature or humidity does not meet the maintenance requirement standard, the spraying is automatically started, and the spraying time, interval time and spraying times can be adjusted according to the current environmental temperature and humidity to meet the standard maintenance index. In addition, the system can automatically generate component maintenance account records, analyze component maintenance indexes, and ensure component quality.

[0084] In some embodiments, the method further comprises: grouting and anchoring the box girder that meets the standard maintenance index and storing.

[0085] The grouting and anchoring operation can be performed within 48 hours after the steel strand bundle of the box girder is tensioned. In the embodiment of the application, the prestressed pipe grouting adopts a vacuum-assisted grouting process, and the specific process flow is as follows:

[0086] Cutting off the exposed steel strand, removing sundries and water in the pipe, sealing the anchor with non-shrinkage cement mortar, cleaning the grouting hole on the anchor pad, determining the vacuum extraction end and the grouting end, installing the lead pipe, ball valve and joint, mixing the cement slurry, starting the vacuum pump to extract vacuum (the vacuum degree reaches-0.06 to-0.08 MPa and remains stable), starting the grouting pump to start grouting (the vacuum pump still continuously operates), closing the valve at the front end of the air filter when the transparent mesh pipe at the vacuum extraction end has slurry passing through, opening the exhaust valve after a while until the cement slurry flows out smoothly, closing all valves at the vacuum extraction end when the slurry consistency is equivalent to the grouting slurry, holding the grouting pump at 0.50 to 0.60 MPa for 3 minutes, closing the grouting pump and the grouting end valve, disassembling the external pipeline, cleaning the air filter and valve, cleaning all equipment with cement slurry, and disassembling and cleaning the ball valve installed at the grouting end and the slurry outlet end after 5 hours.

[0087] Based on the operation flow as above, the prestressed pipe intelligent grouting integrated vehicle is adopted for the grouting and anchoring operation in the embodiment of the application. The vehicle is equipped with an automatic grouting system, which mainly consists of four hardware parts, i.e. grout preparation, vacuum pump, grouting and auxiliary device, and a control system and a data system. The grout preparation device has the functions of automatic feeding, batching, high-speed grouting and low-speed grout storage. The auxiliary part can realize self-diagnosis, self-protection, alarm and early warning, self-cleaning, power-off protection, continuous work and environmental protection dust removal. The data system realizes the informatization management of automatic grouting construction, which is a modern management mode with efficient database as the back-end and visualized charts as the display, and includes 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 hub of realizing the automation, informatization and networking of grouting construction operation and management.

[0088] In the embodiment of the application, the anchorage hole is first chiseled by the anchorage hole chiseling and cutting all-in-one machine before the end sealing, so as to increase the bonding force of the concrete. After the anchorage and the anchorage 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 end sealing concrete is initially cured, the water energy film is used for curing. After the end sealing concrete curing is completed, the polyurethane waterproof paint is used 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 be performed according to the pre-specified process route and mode, and the vibration time of each point should be less than 30 seconds, so as to avoid over-vibration.

[0089] Regarding the storage operation of the box girder, the box girder is stored in double layers in the embodiment of the application.

[0090] (1) Lower layer beam storage: when the beam is hoisted and stored, the top surfaces of the four support cushion stones of the beam storage pedestal are first measured horizontally. 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.

[0091] (2) Upper layer storage beam: when double-layer storage beam, 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 is made of 500*800*50mm rubber support. The center of the supporting point of the lower box girder is 55±50mm away from the beam end in the longitudinal direction, and the transverse distance should be 5200mm, and the supporting area is 500*800mm. When the upper layer storage beam, the distance between the center of the supporting point of the box girder and the beam end 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. At the same time, attention should be paid to observing the flatness of the supporting point in time during construction to ensure that the unevenness of the supporting points of the upper and lower layers is not more than 2mm. It should be noted that double-layer storage beam is only allowed to be stacked according to the above requirements for the same type of box girder, and different span box girders are prohibited from being stacked.

[0092] In order to integrate the whole process 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, the application embodiment can also provide a special identification two-dimensional code for different box girders, so as to realize the whole life cycle information tracing of the box girder. Each box girder corresponds to a special 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, so as to realize the updating of the component progress information, and the detailed visual progress chart of the bridge can be viewed, which provides help for the preparation of the weekly plan from the aspects of vision and data display.

[0093] The above description is only the preferred embodiment of the application and the explanation of the applied technical principles. 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 also covers 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 method for intelligent prefabrication construction of railway box girders, characterized in that, include: According to the production specifications of the beam yard, temporary construction was carried out to build multiple coordinated processing and management units. The processing management unit is 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, the corresponding box girder templates are installed to obtain the first box girder template structure; the box girder templates include at least two models, and the two models of box girder templates can be adjusted by using interchangeable side chamfer templates; the material transportation and distribution center is used to respond to the instructions of the intelligent production and distribution scheduling center to deliver the corresponding model of side chamfer templates; 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 a bound steel bar skeleton; the steel bar processing and distribution center is used to process and distribute the processed steel bars. The hoisting equipment is controlled to place the steel reinforcement cage into the first box girder formwork structure, and the steel reinforcement cage and the first box girder formwork structure are used to pour box girder concrete to obtain the cast box girder body; The first box girder template structure inside the cast box girder is dismantled, and the cast box girder body after the first box girder template structure is dismantled is tensioned to obtain the final box girder. The box girder formwork includes at least: a bottom plate formwork, two side formworks, and two sets of interchangeable side formwork chamfering templates. Each set of side formwork chamfering templates includes two templates. The two ends of the bottom plate formwork are connected to the two side formworks through different sets of side formwork chamfering templates, which can be assembled to obtain box girder formwork of different models. Based on the cooperation of the material transportation and distribution center and the intelligent production and distribution scheduling center, the corresponding box girder formwork is installed to obtain the first box girder formwork structure, including: Obtain the target model of the precast box girder issued by the intelligent production and distribution scheduling center; based on the target model, confirm the group of the required side formwork chamfer template; control the material transportation and distribution center to transport the bottom plate template, two side formwork templates and the corresponding group of side formwork chamfer templates to the site for assembly to obtain the first box girder template structure.

2. The intelligent prefabrication construction method for railway box girders according to claim 1, characterized in that, 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. This includes: selecting the box girder steel bar binding jig corresponding to the first box girder formwork structure; controlling the steel bar processing unit of the steel bar processing and distribution center to process the semi-finished steel bars and transporting the processed steel bars to the box girder steel bar binding jig for binding the box girder steel bars.

3. The intelligent prefabrication construction method for railway box girders according to claim 2, characterized in that, The box girder reinforcement binding fixture includes: a common binding platform, the inner sidewall of which is provided with bottom plate reinforcement clamps corresponding to the two types of box girder templates respectively; different bottom plate reinforcement clamps can be selected to form different box girder reinforcement binding fixtures for use with different types of box girder templates.

4. The intelligent prefabrication construction method for railway box girders according to claim 1, characterized in that, The first box girder formwork structure within the cast-in-place box girder is dismantled, and tensioning is performed on the cast-in-place box girder after the dismantling of the first box girder formwork structure, including: Start the hydraulic system that works in conjunction with the box girder formwork, and use the hydraulic system to dismantle the first box girder formwork structure; Tension force is applied to the cast box girder after the formwork structure of the first box girder is removed, and the tensioning equipment monitors the applied tension force and the elongation value of the prestressed steel bars in real time until the tensioning operation is completed.

5. The intelligent prefabrication construction method for railway box girders according to claim 1, characterized in that, After obtaining the final box girder, the following also includes: Control the beam-moving machine to move the box girder into the beam storage area; During the process of moving the box girder into the storage area, the position, attitude and load of the box girder are monitored in real time; Based on the position, posture, and load, determine whether the box girder has been properly moved into the storage area.

6. The intelligent prefabrication construction method for railway box girders according to claim 5, characterized in that, The beam storage area is equipped with a maintenance monitoring system, and the method further includes: The curing time of each box girder in the storage area and the environmental parameters of the storage area are obtained, including at least temperature and humidity. Based on the environmental parameters, the spraying time, interval, and number of sprays in the beam storage area are controlled until each box girder in the beam storage area meets the standard maintenance indicators.

7. The intelligent prefabrication construction method for railway box girders according to claim 6, characterized in that, The method also includes: grouting and anchoring box girders that meet the standard maintenance indicators and storing them.

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