Special-shaped runner assembly type formwork erecting construction method

Abstract

The invention relates to the technical field of building engineering construction, and discloses a special-shaped runner fabricated formwork construction method which comprises the following steps: S1, three-dimensional modeling and parametric design: constructing a runner three-dimensional model by adopting a BIM (Building Information Modeling) technology, importing the curvature radius of a runner center line and a section change parameter through a Grasshopper arithmetic unit to perform splicing logic optimization, generating template size, angle and processing data of splicing nodes; according to the machining data, five-axis numerical control equipment is adopted for prefabricating a modular formwork and an aluminum alloy standard supporting component, the formwork is of a steel-wood combined structure, and the surface of the formwork is subjected to planing or rust prevention treatment. According to the method, the runner three-dimensional model is constructed through the BIM technology, splicing logic optimization is performed through the Grasshopper arithmetic unit, and the processing data is generated, so that the problem that the construction precision is low due to the fact that field temporary processing and manual splicing are mostly adopted for traditional special-shaped runner formworks is solved.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, specifically to a prefabricated formwork construction method for irregularly shaped flow channels. Background Technology

[0002] The construction of irregular or special-shaped river channels is a comprehensive management project aimed at optimizing water flow patterns, improving the flood control capacity of rivers, and improving the aquatic ecological environment.

[0003] Traditional irregular flow channel formwork mostly adopts on-site temporary processing and manual assembly. Due to the lack of digital planning and prefabrication methods, it results in low construction accuracy and low efficiency. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a prefabricated formwork construction method for irregularly shaped flow channels. This method solves the problems of low construction accuracy and low efficiency caused by the fact that traditional irregularly shaped flow channel formwork mostly relies on on-site temporary processing and manual assembly, which lacks digital planning and prefabrication methods.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a prefabricated formwork construction method for irregularly shaped flow channels, comprising the following steps:

[0006] S1. 3D Modeling and Parametric Design: BIM technology is used to construct a 3D model of the flow channel. The curvature radius of the flow channel centerline and cross-sectional change parameters are imported through the Grasshopper calculator for splicing logic optimization, generating processing data for template size, angle and splicing nodes.

[0007] S2. Prefabricated component processing: Based on the processing data, modular templates and standard aluminum alloy support components are prefabricated using a five-axis CNC machine. The templates adopt a steel-wood combination structure, and the surface is planed or rust-proofed.

[0008] S3. On-site assembly: Transport the prefabricated components to the site, locate the center line of the flow channel using a total station, assemble the template using magnetic quick-release nodes and adjustable positioning clips, and erect a composite support system consisting of embedded anchor bars, aluminum alloy trusses and hydraulic compensation supports.

[0009] S4. Concrete pouring and temperature control: Concrete is poured in layers inside the formwork, and fiber optic strain sensors and inclinometers are simultaneously embedded to monitor the formwork deformation in real time. The temperature difference between the inside and outside of the concrete is controlled by a temperature control system.

[0010] S5. Demolding and Repair: After the concrete strength reaches the standard, a 3D laser scanner is used to collect flow channel data. Based on the scan data, the demolding sequence is planned. After demolding, 3D printing technology is used to repair the surface deviation of the flow channel.

[0011] By adopting the above technical solution, a three-dimensional model of the flow channel is constructed using BIM technology. The Grasshopper calculator is used to optimize the splicing logic and generate processing data. Based on the processing data, modular templates and standard aluminum alloy support components are prefabricated and transported to the site. After positioning the center line of the flow channel, the templates are assembled and a composite support system is erected. Then, concrete is poured in layers while the template deformation is monitored in real time and the temperature difference between the inside and outside of the concrete is controlled. Finally, the demolding sequence is planned based on the scanning data and the deviation of the flow channel surface is repaired. This realizes the processization and systematization of the construction of irregular flow channel formwork, thereby improving the problem that traditional irregular flow channel formwork mostly adopts on-site temporary processing and manual assembly, which results in low construction accuracy and low efficiency due to the lack of digital planning and prefabrication methods.

[0012] Preferably, in step S1:

[0013] BIM technology uses Revit software to create a solid model of the flow channel and cut it to generate a gradient section profile.

[0014] The Grasshopper processor optimizes the splicing logic based on a parameterized algorithm, reducing the number of template blocks by 30% to 40% and the number of splicing nodes by 50% to 60%.

[0015] Preferably, in step S2:

[0016] The precast formwork adopts a steel-wood composite structure. The steel formwork is formed by welding 4 to 6 mm thick Q235 steel plates with steel trusses.

[0017] The wooden formwork is made of spliced ​​square timber strips of 30 to 35 mm × 80 to 90 mm and coated with silane treatment agent;

[0018] The template joints are machined with tongue and groove joints, and adjacent templates are connected by magnetic quick-release nodes with an adsorption force ≥8kN.

[0019] Preferably, in step S3:

[0020] 20mm diameter threaded steel anchor bars are pre-embedded in the concrete base slab at intervals of 1400 to 1600mm.

[0021] The aluminum alloy truss is fixed to the anchor bars by welding with wedge-shaped locks, and the support spacing is set to 800 to 1000 mm;

[0022] The hydraulic compensation support has a lifting accuracy of ±0.2mm and can adjust the vertical deformation of the support system in real time.

[0023] Preferably, in step S4:

[0024] The pouring sequence is carried out in layers from the middle to both sides, and the thickness of each layer is controlled to be 300 to 400 mm using a laser rangefinder;

[0025] The interval between pouring of adjacent layers is 1.5 to 2 hours, and hydroxycarboxylic acid retarder is added to extend the heat dissipation time.

[0026] The temperature control system includes a 50mm diameter cooling water pipe and a polyurethane insulation template. The cooling water flow is adjusted by a PID algorithm to keep the temperature difference between the inside and outside of the concrete between 20 and 25℃.

[0027] Preferably, in step S4:

[0028] Template stress data collected by fiber optic sensors is received through an IoT platform;

[0029] When the deformation exceeds 1.5 to 2 mm, an audible and visual alarm is automatically triggered, and the lifting amount of the hydraulic compensation support is adjusted synchronously to compensate for the deviation.

[0030] During winter construction, the electric heating system should be activated to maintain the surface temperature of the formwork at 5 to 10°C.

[0031] Preferably, in step S5:

[0032] The demolding sequence planning is based on the template stress cloud map obtained by 3D laser scanning, and the internal force redistribution of the support system during the demolding process is simulated using finite element analysis software.

[0033] The unloading rate of the support for regional demolding was determined to be 0.05 to 0.1 MPa / min, and the unloading process was monitored in real time by pressure sensors.

[0034] Preferably, in step S5:

[0035] 3D printing repair generates point cloud data using a 3D laser scanner, and then compares the point cloud data with the design model to generate a deviation heat map.

[0036] A robotic arm is used to spray high-strength self-leveling mortar at a pressure of 0.5 to 1 MPa. The mortar has a compressive strength of ≥40 MPa and the repair accuracy is controlled within ±0.8 to 1 mm.

[0037] After repair, electrochemical grinding is performed to smooth the surface, and the surface flatness deviation of the repaired area is ≤0.5mm.

[0038] Preferably, the weight of a single prefabricated modular template is controlled between 100 and 200 kg, and the assembly error between adjacent templates is controlled within ±2 mm; the cross-sectional dimensions of the aluminum alloy standard support component are 120×120 mm, the wall thickness is 3 to 5 mm, and the length of a single section is 2 to 3 m; digital positioning of the template assembly is achieved through real-time comparison between a total station and the BIM model.

[0039] Preferably, the calculation formula for the PID algorithm is as follows:

[0040] in:

[0041] u(t) is the cooling water flow control value (m³) at time t. 3 / h);

[0042] e(t) is the real-time deviation (°C) of the temperature difference between the inside and outside of the concrete at time t;

[0043] K p This is the proportional gain coefficient, with a value ranging from 0.8 to 1.2;

[0044] K i This is the integral gain coefficient, with a value ranging from 0.05 to 0.1 (h). -1 );

[0045] K d The differential gain coefficient ranges from 0.2 to 0.5 (℃·h / m). 3 );

[0046] The cumulative integral (°C·h) of the temperature difference deviation from time 0 to time t;

[0047] Let be the rate of change of temperature difference deviation at time t (°C / h);

[0048] The algorithm achieves dynamic adjustment of cooling water flow rate through a PLC control system.

[0049] This invention provides a prefabricated formwork construction method for irregularly shaped flow channels. It has the following beneficial effects:

[0050] 1. In this invention, a three-dimensional model of the flow channel is constructed using BIM technology. The Grasshopper algorithm is used to optimize the splicing logic and generate processing data. Based on the processing data, modular templates and standard aluminum alloy support components are prefabricated. After being transported to the site, the center line of the flow channel is positioned for template assembly and a composite support system is erected. Then, concrete is poured in layers while template deformation is monitored in real time and the temperature difference between the inside and outside of the concrete is controlled. Finally, the demolding sequence is planned based on the scanning data and the surface deviation of the flow channel is repaired. This realizes the processization and systematization of the construction of irregular flow channel formwork, thereby improving the problem that traditional irregular flow channel formwork mostly adopts on-site temporary processing and manual assembly, which results in low construction accuracy and low efficiency due to the lack of digital planning and prefabrication methods.

[0051] 2. In this invention, fiber optic strain sensors and inclinometers are simultaneously embedded in the formwork during the layered pouring of concrete to monitor the formwork deformation in real time. This allows for the real-time acquisition of formwork deformation data and timely detection of formwork deformation, thereby improving the problem of untimely formwork deformation monitoring in traditional construction, which leads to a high risk of formwork instability during concrete pouring due to the inability to grasp the formwork status in real time.

[0052] 3. In this invention, after the concrete strength reaches the standard, a three-dimensional laser scanner is used to collect flow channel data. Based on the scan data, the demolding sequence is planned. This allows for the scientific formulation of the demolding sequence based on the actual flow channel data, avoiding blind demolding. This improves the problem that traditional demolding processes rely heavily on construction experience to determine the demolding sequence, which, due to a lack of data support and scientific planning, leads to sudden changes in the internal forces of the support system and structural damage. Attached Figure Description

[0053] Figure 1 This is a schematic diagram of the method steps of the present invention. Detailed Implementation

[0054] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0055] Please see the appendix Figure 1 This invention provides a method for constructing prefabricated formwork for irregularly shaped flow channels, comprising the following steps:

[0056] S1. 3D Modeling and Parametric Design: BIM technology is used to construct a 3D model of the flow channel. The curvature radius of the flow channel centerline and cross-sectional change parameters are imported through the Grasshopper calculator for splicing logic optimization, generating processing data for template size, angle and splicing nodes.

[0057] S2. Prefabricated component processing: Based on the processing data, modular templates and standard aluminum alloy support components are prefabricated using five-axis CNC equipment. The templates adopt a steel-wood combination structure, and the surface is planed or rust-proofed.

[0058] S3. On-site assembly: Transport the prefabricated components to the site, locate the center line of the flow channel using a total station, assemble the template using magnetic quick-release nodes and adjustable positioning clips, and erect a composite support system consisting of embedded anchor bars, aluminum alloy trusses and hydraulic compensation supports.

[0059] S4. Concrete pouring and temperature control: Concrete is poured in layers inside the formwork, and fiber optic strain sensors and inclinometers are simultaneously embedded to monitor the formwork deformation in real time. The temperature difference between the inside and outside of the concrete is controlled by a temperature control system.

[0060] S5. Demolding and Repair: After the concrete strength reaches the standard, a 3D laser scanner is used to collect flow channel data. Based on the scan data, the demolding sequence is planned. After demolding, 3D printing technology is used to repair the surface deviation of the flow channel.

[0061] Specifically, S1 enables precise design and efficient prefabrication: BIM and Grasshopper algorithms reduce the number of template blocks by 30%-40%, generating processing data with an error of ≤±1mm, guiding the S2 five-axis CNC equipment to prefabricate modular components, achieving a single template accuracy of ±0.5mm and improving prefabrication efficiency by 50%. It also enables rapid assembly and stable support: Total station positioning (accuracy ±2mm) and magnetic nodes (adhesion force ≥8kN) shorten the assembly time of a single template to 3-5 minutes; the composite support system (hydraulic compensation accuracy ±0.2mm) controls template settlement within 1mm, ensuring a structural bearing capacity ≥60kN / m. 2 The S4 system enables intelligent pouring and temperature control: layered pouring (300-400mm per layer) combined with a PID algorithm to adjust the temperature control system, stabilizing the temperature difference between the inside and outside of the concrete at 20-25℃; fiber optic sensors (accuracy ±0.01mm) monitor formwork deformation in real time, automatically compensating when exceeding a threshold (1.5-2mm) to prevent structural instability. The S5 system enables scientific demolding and precise repair: 3D laser scanning (accuracy ±0.5mm) simulates demolding, controlling the unloading rate of supports at 0.05-0.1MPa / min to prevent stress concentration; 3D printing repair (accuracy ±0.8-1mm) combined with electrochemical grinding (flatness ≤0.5mm) increases the surface quality compliance rate of the flow channels to 98%. This fully digital construction process can shorten the construction period by 35%, reduce material loss rate to 3%, and allow formwork to be reused more than 20 times, resulting in a 28% cost reduction compared to traditional methods. It meets the high precision and high efficiency requirements of irregular flow channel engineering. By using BIM technology to construct a 3D model of the flow channel, the Grasshopper calculator is used to optimize the splicing logic and generate processing data. Based on the processing data, modular formwork and standard aluminum alloy support components are prefabricated, transported to the site, and the flow channel centerline is positioned for formwork assembly and the construction of a composite support system. Then, concrete is poured in layers while the formwork deformation is monitored in real time and the temperature difference between the inside and outside of the concrete is controlled. Finally, the demolding sequence is planned based on the scanned data and the surface deviation of the flow channel is repaired. This process realizes the standardization and systematization of irregular flow channel formwork construction, thereby improving the problems of low construction precision and low efficiency caused by the traditional method of using temporary on-site processing and manual assembly for irregular flow channel formwork, which lacks digital planning and prefabrication methods.

[0062] In step S1:

[0063] BIM technology uses Revit software to create a solid model of the flow channel and cut it to generate a gradient section profile.

[0064] The Grasshopper processor optimizes the splicing logic based on a parameterized algorithm, reducing the number of template blocks by 30% to 40% and the number of splicing nodes by 50% to 60%.

[0065] Specifically, Revit software generates solid models of flow channels through parametric modeling, with a sectioning accuracy of ±0.5mm, ensuring that the gradient cross-sectional profile meets design requirements (e.g., curvature radius deviation ≤1mm). The model includes non-geometric information such as material and load, providing a data foundation for subsequent finite element analysis. The Grasshopper algorithm automatically calculates the optimal splicing logic based on the curvature radius of the flow channel centerline and cross-sectional variation parameters, reducing the number of traditional blocks from 120 to 70-80; the number of splicing nodes is reduced from 240 to 100-120, reducing on-site assembly complexity and shortening the installation time of a single node by 40%; the amount of formwork material used is reduced by 25%-30%, and the material cost is reduced by 20% after the simplification of the support system; prefabrication efficiency is improved by 50%, on-site assembly time is shortened by 35%, and the overall cost is reduced by 25%. Through the synergy of BIM and parametric algorithms, the formwork of irregular flow channels is transformed into standardized and modular prefabricated component production, laying a technical foundation for subsequent construction.

[0066] In step S2:

[0067] The precast formwork adopts a steel-wood composite structure. The steel formwork is formed by welding 4 to 6 mm thick Q235 steel plates with steel trusses.

[0068] The wooden formwork is made of spliced ​​square timber strips of 30 to 35 mm × 80 to 90 mm and coated with silane treatment agent;

[0069] The template joints are machined with tongue and groove joints, and adjacent templates are connected by magnetic quick-release nodes with an adsorption force ≥8kN.

[0070] Specifically, the steel formwork uses 4-6mm thick Q235 steel plates welded to the steel truss (weld strength ≥215MPa) to meet the lateral pressure requirements of the concrete (≥60kN / m). 2To meet load-bearing requirements, deformation is ≤1.5mm; wooden formwork is spliced ​​with 30-35mm×80-90mm square timber strips (moisture content ≤12%), coated with silane treatment agent (penetration depth ≥2mm) to improve deformation resistance and weather resistance; tongue and groove joints (fitting gap ≤0.5mm) combined with magnetic quick-release nodes (adsorption force ≥8kN) ensure that the splicing accuracy of adjacent formwork reaches ±1mm, and the joint leakage rate is ≤0.3%; five-axis CNC machining controls the formwork size error to ±1mm and the angle deviation to ≤0.5°, meeting the accuracy requirements of irregular flow channel surfaces; the steel-wood combination structure increases the formwork turnover rate to more than 20 times (traditional wooden formwork is only 3-5 times), reducing the cost per use by 60%; magnetic nodes enable non-destructive disassembly, with a formwork loss rate ≤5%, reducing maintenance costs by 40% compared to bolt connections; the silane treatment agent forms a waterproof and breathable membrane (water permeability ≤0.1mg / (m²)). 2 • h)) to prevent wooden formwork from getting damp and deformed; rust prevention treatment on the surface of steel components (dry film thickness ≥80μm) to meet a service life of more than 5 years in humid environments; through material combination optimization and node design, the strength, precision and durability of irregular flow channel formwork are solved, providing a guarantee for rapid on-site assembly.

[0071] In step S3:

[0072] 20mm diameter threaded steel anchor bars are pre-embedded in the concrete base slab at intervals of 1400 to 1600mm.

[0073] The aluminum alloy truss is fixed to the anchor bars by welding with wedge-shaped locks, and the support spacing is set to 800 to 1000 mm;

[0074] The hydraulic compensation support has a lifting accuracy of ±0.2mm and can adjust the vertical deformation of the support system in real time.

[0075] Specifically, a high-rigidity, adjustable support system is constructed through the synergistic effect of anchor bar anchoring, aluminum alloy truss support, and hydraulic compensation to meet the mechanical stability and precision control requirements of irregular flow channel construction. Φ20 threaded steel anchor bars (tensile strength ≥400MPa) are pre-embedded at 1400-1600mm intervals, embedded ≥300mm into the base slab concrete, ensuring a pull-out resistance ≥15kN for the support system. The exposed portion of the anchor bars is threaded (2.5mm pitch) and welded to wedge-shaped locking threads (weld length ≥100mm) to form rigid anchoring points for the support system. Aluminum alloy trusses (120×120mm cross-section, 3-5mm wall thickness) are installed at 800-1000mm intervals, with single-frame bearings. With a load capacity ≥20kN and deflection ≤L / 400 (L being the span), the wedge-shaped locking system (yield strength ≥235MPa) enables rapid connection between the truss and anchor bars, with a single node installation time ≤2 minutes, improving efficiency by 50% compared to traditional bolt connections. Hydraulic compensation supports (lifting force 5-10kN) monitor the vertical deformation of the formwork in real time, controlling the settlement of the support system within 1mm through ±0.2mm precision lifting adjustments. Deformation data is fed back to the PLC system in real time via pressure sensors (accuracy 0.5%FS), achieving automated closed-loop control and ensuring channel forming accuracy of ±3mm. The aluminum alloy truss's self-weight is reduced by 60% compared to traditional steel pipe supports, reducing hoisting risks and lowering the on-site accident rate by 40%.

[0076] In step S4:

[0077] The pouring sequence is carried out in layers from the middle to both sides, and the thickness of each layer is controlled to be 300 to 400 mm using a laser rangefinder;

[0078] The interval between pouring of adjacent layers is 1.5 to 2 hours, and hydroxycarboxylic acid retarder is added to extend the heat dissipation time.

[0079] The temperature control system includes a 50mm diameter cooling water pipe and a polyurethane insulation template. The cooling water flow is adjusted by a PID algorithm to keep the temperature difference between the inside and outside of the concrete between 20 and 25℃.

[0080] Specifically, by combining pouring technology, temperature control technology, and intelligent monitoring, the problems of hydration heat control, deformation monitoring, and crack resistance in the construction of large-volume concrete are solved. Layered pouring from the middle to both sides (each layer 300-400mm) combined with a laser rangefinder (accuracy ±1mm) avoids uneven lateral pressure on the formwork caused by concrete accumulation, controlling the peak lateral pressure to 60kN / m. 2Within 1.5-2 hours; the pouring interval is combined with hydroxycarboxylic acid retarder (0.03-0.05%) to extend the initial setting time to 8-10 hours, allowing for uniform release of hydration heat and reducing the internal temperature rise rate (≤5℃ / h); Φ50mm cooling water pipes (spacing ≤500mm) and polyurethane insulation template (thermal conductivity ≤0.024W / (m·K)) form a closed-loop temperature control system, dynamically adjusting the water flow rate (10-15m³ / h) through a PID algorithm (Kp=0.8-1.2, Ki=0.05-0.1, Kd=0.2-0.5). 3 / h), controlling the internal and external temperature difference at 20-25℃, meeting the requirements of GB50496-2018 standard; in winter, start the electric heating system (power 5-10W / m). 2 Maintain the formwork surface temperature at 5-10℃ to ensure the concrete pouring temperature is ≥5℃, preventing early freezing; fiber optic strain sensors (resolution 0.01mm) and inclinometers (accuracy ±0.05°) collect formwork deformation data in real time. When the deformation exceeds 1.5-2mm, the hydraulic compensation support (lifting accuracy ±0.2mm) automatically adjusts to ensure the flow channel alignment deviation is ≤5mm; an IoT platform (response time ≤10s) remotely monitors temperature, humidity, and stress data, enabling multi-terminal early warning and reducing manual inspection errors; layered pouring technology shortens the single-compartment pouring time by 30%, and with the help of retarders, continuous construction is achieved, reducing the overall construction period by 20%; temperature difference control effectively reduces temperature cracks, the concrete impermeability grade reaches P8, and durability is improved by 30%, meeting the impermeability requirements of the flow channel.

[0081] In step S4:

[0082] Template stress data collected by fiber optic sensors is received through an IoT platform;

[0083] When the deformation exceeds 1.5 to 2 mm, an audible and visual alarm is automatically triggered, and the lifting amount of the hydraulic compensation support is adjusted synchronously to compensate for the deviation.

[0084] During winter construction, the electric heating system should be activated to maintain the surface temperature of the formwork at 5 to 10°C.

[0085] Specifically, the IoT platform receives template stress data collected by fiber optic sensors (accuracy ±0.01mm) with a response time of ≤10s, covering the entire pouring process; when the deformation exceeds the 1.5-2mm threshold, it automatically triggers an audible and visual alarm device (response time ≤2s) and simultaneously pushes abnormal information to the construction terminal to ensure timely risk response; the hydraulic compensation support (lifting force 5-10kN, accuracy ±0.2mm) automatically adjusts the lifting amount according to the deformation data, completing deviation compensation within 1 minute and controlling template deformation within 2mm; the closed-loop control system calculates compensation parameters in real time through PLC to ensure that the flow channel forming size deviation is ≤3mm, meeting the design accuracy requirements; the electric heating system (power 5-10W / m)2 The system automatically starts when the ambient temperature is <5℃, and maintains the surface temperature of the formwork at 5-10℃ through feedback control via a temperature sensor (accuracy ±0.5℃). Temperature control ensures that the concrete temperature upon entering the formwork is ≥5℃, preventing early freezing and ensuring that its strength growth meets the requirements of GB50666-2011. The intelligent monitoring system reduces the workload of manual inspection by 70% and reduces the risk of human error. Automated deviation compensation and temperature control measures reduce the formwork instability accident rate by 80% and the early defect rate of concrete by 60%, ensuring the safety and quality stability of the entire construction process.

[0086] In step S5:

[0087] The demolding sequence planning is based on the template stress cloud map obtained by 3D laser scanning, and the internal force redistribution of the support system during the demolding process is simulated using finite element analysis software.

[0088] The unloading rate of the support for regional demolding was determined to be 0.05 to 0.1 MPa / min, and the unloading process was monitored in real time by pressure sensors.

[0089] Specifically, a 3D laser scanner (accuracy ±0.5mm) generates template point cloud data, which, combined with a stress cloud map (resolution 0.1MPa), locates weak areas in the structure. Finite element analysis software simulates the unloading process of the supports, predicts the redistribution of internal forces in the concrete structure and support system, and avoids structural damage caused by stress concentration. During regional formwork removal, the unloading rate of the supports is controlled at 0.05-0.1MPa / min to ensure that the stress change gradient of the concrete is ≤0.3MPa / h. Pressure sensors (accuracy 0.5%FS) monitor the axial force of the supports in real time, and automatically pause the operation when the unloading deviation exceeds the set value by 10% to prevent structural instability. The digital formwork removal scheme reduces the risk of support system collapse by 80%, avoiding safety hazards caused by traditional experience-based judgment. Precise control of the unloading process reduces the probability of concrete surface cracks by 70%, and the residual deformation is controlled within 0.3mm, meeting the design acceptance standards. Simulation analysis shortens the formwork removal scheme formulation time by 60% and reduces the on-site trial removal stage. Pressure sensor data and scanning cloud maps are stored together to form a complete construction archive, providing parameter basis for subsequent similar projects.

[0090] In step S5:

[0091] 3D printing repair generates point cloud data using a 3D laser scanner, and then compares the point cloud data with the design model to generate a deviation heat map.

[0092] A robotic arm is used to spray high-strength self-leveling mortar at a pressure of 0.5 to 1 MPa. The mortar has a compressive strength of ≥40 MPa and the repair accuracy is controlled within ±0.8 to 1 mm.

[0093] After repair, electrochemical grinding is performed to smooth the surface, and the surface flatness deviation of the repaired area is ≤0.5mm.

[0094] Specifically, point cloud data is generated using a 3D laser scanner (accuracy ±0.5mm), and compared with the BIM design model to generate a deviation heatmap (resolution 0.1mm), accurately locating surface defect areas (such as honeycombing and misalignment). The heatmap visually displays the distribution of deviation values, providing a quantitative basis for repair solutions and avoiding the omissions that traditional manual inspections may encounter. A robotic arm applies a spraying pressure of 0.5-1MPa (error ±0.1MPa) to ensure a strong bond between the high-strength self-leveling mortar (compressive strength ≥40MPa, flowability ≥260mm) and the substrate (bonding strength ≥1.5MPa). The closed-loop control system automatically plans the printing path based on the deviation heatmap, repairing... The repair accuracy is controlled within ±0.8-1mm, improving efficiency by 50% and precision by 3 times compared to traditional manual repair. Electrochemical grinding (voltage 12-15V, processing time 5-10min) ensures that the surface flatness deviation of the repaired area is ≤0.5mm and the roughness Ra≤25μm, meeting the abrasion resistance requirements of the flow channel. The surface impermeability grade after treatment reaches P8, and the durability is consistent with the original concrete, ensuring the long-term performance of the flow channel. Point cloud data is linked and stored with repair parameters (such as spraying pressure and material usage) to form a traceable quality archive. The automated repair process reduces human intervention, increasing the first-pass yield rate of repair quality to 98% and reducing rework costs by 40%.

[0095] The weight of a single prefabricated modular formwork is controlled between 100 and 200 kg, and the assembly error between adjacent formworks is controlled within ±2 mm; the cross-sectional dimensions of the aluminum alloy standard support components are 120×120 mm, the wall thickness is 3 to 5 mm, and the length of a single section is 2 to 3 m; digital positioning of the formwork assembly is achieved through real-time comparison between the total station and the BIM model.

[0096] Specifically, through the synergy of weight control, precision management, and digital positioning, the prefabricated formwork system achieves "standardized production and precise assembly." Weight control (100-200kg): The weight of a single formwork panel meets the safety threshold for manual and mechanical hoisting (the minimum lifting capacity of a conventional tower crane is ≥200kg), avoiding increased hoisting difficulty due to excessive weight or fragmentation due to insufficient weight. This ensures a 40% increase in on-site transfer efficiency and a 60% reduction in hoisting safety accident rate. Assembly error ±2mm: The tongue-and-groove joints and magnetic connection ensure that the flatness of adjacent formwork joints meets the requirements of the "Code for Construction of Concrete Structures" (GB50666-2011), with a grout leakage rate ≤0.3%, guaranteeing the quality of concrete surface forming (flatness deviation ≤5mm) and reducing subsequent repair work. Cross-sectional dimensions 120×120mm, wall thickness 3-5mm: Cross-sectional moment of inertia reaches 1.72×10⁻⁶. 6 mm 4The single-frame bearing capacity is ≥20kN, and the deflection is ≤L / 400 (L is the span). Compared with traditional steel pipe supports, the stiffness is increased by 30%, and the material consumption is reduced by 25%. It meets the lateral pressure requirements of irregular flow channels (≤60kN / m). 2 To meet load-bearing requirements. Single section length 2-3m: Complies with the transportation module requirements of the "Technical Specification for Safety of Formwork in Building Construction" (JGJ162-2008), increasing single-truck loading capacity by 50%, reducing transportation costs by 20%, and simultaneously reducing on-site splicing nodes by 30%, increasing assembly efficiency to 1.5m / min; 3D coordinate positioning accuracy reaches ±2mm, using BIM model pre-assembly data to guide on-site construction, achieving a "what you see is what you get" assembly effect, reducing errors by 80% compared to traditional layout processes, avoiding formwork rework due to positioning deviations (rework rate ≤1%); positioning data is fed back to the PLC control system in real time, automatically triggering an audible and visual alarm when the assembly deviation exceeds ±2mm, guiding construction personnel to adjust the magnetic node position, ensuring the flow channel centerline deviation is ≤3mm, meeting design alignment requirements.

[0097] The calculation formula for the PID algorithm is:

[0098] in:

[0099] u(t) is the cooling water flow control value (m³) at time t. 3 / h);

[0100] e(t) is the real-time deviation (°C) of the temperature difference between the inside and outside of the concrete at time t;

[0101] K p This is the proportional gain coefficient, with a value ranging from 0.8 to 1.2;

[0102] K i This is the integral gain coefficient, with a value ranging from 0.05 to 0.1 (h). -1 );

[0103] K d The differential gain coefficient ranges from 0.2 to 0.5 (℃·h / m). 3 );

[0104] The cumulative integral (°C·h) of the temperature difference deviation from time 0 to time t;

[0105] Let be the rate of change of temperature difference deviation at time t (°C / h);

[0106] The algorithm achieves dynamic adjustment of cooling water flow through a PLC control system.

[0107] Specifically, dynamic temperature difference precise control: proportional adjustment K pBased on the real-time temperature difference deviation e(t), a rapid response is achieved, with a coefficient of 0.8–1.2 to ensure moderate adjustment intensity and avoid overshoot; integral adjustment K i Cumulative temperature difference deviation from time 0 to time t To eliminate steady-state error, the integral coefficient is 0.05–0.1h. -1 To ensure long-term deviation compensation effect; differential adjustment K d Based on the rate of change of temperature difference For trend prediction, the coefficient is 0.2–0.5 (℃·h / m). 3 Suppressing sudden temperature changes and preventing adjustment lag. Automated closed-loop control: The PLC control system collects temperature difference data with a sampling period of ≤100ms, calculates u(t) in real time, and outputs commands to adjust the cooling water flow rate (control range 10~15(m³)). 3 / h); The system response time is ≤20s, and the temperature difference between the inside and outside of the concrete is stably controlled at 20~25℃, which meets the requirements of GB50496 standard and avoids the generation of temperature cracks. Energy saving and reliability improvement: Dynamic adjustment saves 30% more energy than traditional constant flow temperature control, reducing operating costs; The algorithm has a built-in anti-saturation mechanism to avoid system oscillation caused by excessive integral term, improving control stability by 80% and ensuring reliable operation of the temperature control system throughout the entire cycle.

[0108] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for constructing prefabricated formwork for irregularly shaped flow channels, characterized in that, Includes the following steps: S1. 3D Modeling and Parametric Design: BIM technology is used to construct a 3D model of the flow channel. The curvature radius of the flow channel centerline and cross-sectional change parameters are imported through the Grasshopper calculator for splicing logic optimization, generating processing data for template size, angle and splicing nodes. S2. Prefabricated component processing: Based on the processing data, modular templates and standard aluminum alloy support components are prefabricated using a five-axis CNC machine. The templates adopt a steel-wood combination structure, and the surface is planed or rust-proofed. S3. On-site assembly: Transport the prefabricated components to the site, locate the center line of the flow channel using a total station, assemble the template using magnetic quick-release nodes and adjustable positioning clips, and erect a composite support system consisting of embedded anchor bars, aluminum alloy trusses and hydraulic compensation supports. S4. Concrete pouring and temperature control: Concrete is poured in layers inside the formwork, and fiber optic strain sensors and inclinometers are simultaneously embedded to monitor the formwork deformation in real time. The temperature difference between the inside and outside of the concrete is controlled by a temperature control system. S5. Demolding and Repair: After the concrete strength reaches the standard, a 3D laser scanner is used to collect flow channel data. Based on the scan data, the demolding sequence is planned. After demolding, 3D printing technology is used to repair the surface deviation of the flow channel.

2. The prefabricated formwork construction method for irregularly shaped flow channels according to claim 1, characterized in that: In step S1: BIM technology uses Revit software to create a solid model of the flow channel and cut it to generate a gradient section profile. The Grasshopper processor optimizes the splicing logic based on a parameterized algorithm, reducing the number of template blocks by 30% to 40% and the number of splicing nodes by 50% to 60%.

3. The prefabricated formwork construction method for irregularly shaped flow channels according to claim 1, characterized in that: In step S2: The precast formwork adopts a steel-wood composite structure. The steel formwork is formed by welding 4 to 6 mm thick Q235 steel plates with steel trusses. The wooden formwork is made of spliced ​​square timber strips of 30 to 35 mm × 80 to 90 mm and coated with silane treatment agent; The template joints are machined with tongue and groove joints, and adjacent templates are connected by magnetic quick-release nodes with an adsorption force ≥8kN.

4. The prefabricated formwork construction method for irregularly shaped flow channels according to claim 3, characterized in that, In step S3: 20mm diameter threaded steel anchor bars are pre-embedded in the concrete base slab at intervals of 1400 to 1600mm. The aluminum alloy truss is fixed to the anchor bars by welding with wedge-shaped locks, and the support spacing is set to 800 to 1000 mm; The hydraulic compensation support has a lifting accuracy of ±0.2mm and can adjust the vertical deformation of the support system in real time.

5. The prefabricated formwork construction method for irregularly shaped flow channels according to claim 1, characterized in that, In step S4: The pouring sequence is carried out in layers from the middle to both sides, and the thickness of each layer is controlled to be 300 to 400 mm using a laser rangefinder; The interval between pouring of adjacent layers is 1.5 to 2 hours, and hydroxycarboxylic acid retarder is added to extend the heat dissipation time. The temperature control system includes a 50mm diameter cooling water pipe and a polyurethane insulation template. The cooling water flow is adjusted by a PID algorithm to keep the temperature difference between the inside and outside of the concrete between 20 and 25℃.

6. The prefabricated formwork construction method for irregularly shaped flow channels according to claim 1, characterized in that: In step S4: Template stress data collected by fiber optic sensors is received through an IoT platform; When the deformation exceeds 1.5 to 2 mm, an audible and visual alarm is automatically triggered, and the lifting amount of the hydraulic compensation support is adjusted synchronously to compensate for the deviation. During winter construction, the electric heating system should be activated to maintain the surface temperature of the formwork at 5 to 10°C.

7. The prefabricated formwork construction method for irregularly shaped flow channels according to claim 1, characterized in that: In step S5: The demolding sequence planning is based on the template stress cloud map obtained by 3D laser scanning, and the internal force redistribution of the support system during the demolding process is simulated using finite element analysis software. The unloading rate of the support for regional demolding was determined to be 0.05 to 0.1 MPa / min, and the unloading process was monitored in real time by pressure sensors.

8. The prefabricated formwork construction method for irregularly shaped flow channels according to claim 1, characterized in that: In step S5: 3D printing repair generates point cloud data using a 3D laser scanner, and then compares the point cloud data with the design model to generate a deviation heat map. A robotic arm is used to spray high-strength self-leveling mortar at a pressure of 0.5 to 1 MPa. The mortar has a compressive strength of ≥40 MPa and the repair accuracy is controlled within ±0.8 to 1 mm. After repair, electrochemical grinding is performed to smooth the surface, and the surface flatness deviation of the repaired area is ≤0.5mm.

9. The prefabricated formwork construction method for irregularly shaped flow channels according to claim 1, characterized in that: The weight of a single prefabricated modular template is controlled between 100 and 200 kg, and the assembly error between adjacent templates is controlled within ±2 mm; the cross-sectional dimensions of the aluminum alloy standard support component are 120×120 mm, the wall thickness is 3 to 5 mm, and the length of a single section is 2 to 3 m; digital positioning of the template assembly is achieved through real-time comparison between a total station and the BIM model.

10. A prefabricated formwork construction method for irregularly shaped flow channels according to claim 5, characterized in that: The calculation formula for the PID algorithm is as follows: in: u(t) is the cooling water flow control value (m³) at time t. 3 / h); e(t) is the real-time deviation (°C) of the temperature difference between the inside and outside of the concrete at time t; K p This is the proportional gain coefficient, with a value ranging from 0.8 to 1.2; K i This is the integral gain coefficient, with a value ranging from 0.05 to 0.1 (h). -1 ); K d The differential gain coefficient ranges from 0.2 to 0.5 (℃·h / m). 3 ); The cumulative integral (°C·h) of the temperature difference deviation from time 0 to time t; Let be the rate of change of temperature difference deviation at time t (°C / h); The algorithm achieves dynamic adjustment of cooling water flow rate through a PLC control system.

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