Deepening method of large aluminum mold of outer wall for air factory building mold template suspension system

Abstract

The application relates to the field of air building factory construction, and discloses a deepening method of an outer wall aluminum mold large mold matched with an air building factory template suspension system; in the method, the large mold plate adopts an integral block overall height structure, a special general plate is arranged at the bottom and connected through a screw rod, the large mold plate is provided with multiple rows of screw rod holes for fixing and preventing mold expansion, a lifting point is hoisted through cooperation of an aluminum mold side rib screw rod hole and a buckle, and the special general plate is removed and vertically transported based on a walkway plate; the method solves the problems of poor general plate connection, unstable large mold plate and low transportation efficiency, and guarantees the outer wall construction quality and efficiency.

Description

Technical Field

[0001] This invention relates to the field of aerial building factory construction, specifically a method for deepening the large-scale aluminum formwork of the exterior wall in conjunction with the formwork suspension system of the aerial building factory. Background Technology

[0002] In the construction of exterior walls in conjunction with the formwork suspension system of the aerial building factory, the aluminum formwork needs to be deepened into large formwork to adapt to the suspension system. However, the existing large formwork deepening solution has a core flaw. The existing solution uses 200mm high ordinary slabs, and these slabs cannot be effectively connected to the old wall using bolts. They rely solely on diagonal pressure reinforcement with back ribs, which is a complex reinforcement process and prone to grout leakage at the junction of the exterior wall and the floor, directly causing the verticality and flatness of the exterior wall to exceed the standards. At the same time, the bolt hole arrangement of the large formwork has not been verified by system stress calculation, and it cannot adapt to the structural characteristics of the large formwork with its continuous height, which is prone to uneven stress on the formwork and increases the risk of formwork bulging. In addition, there is a lack of dedicated vertical transportation equipment after the ordinary slabs are removed, requiring manual transfer and being easily affected by the construction environment. This is incompatible with the high-efficiency construction characteristics of the aerial building factory, seriously affecting the construction quality and progress.

[0003] Based on the above problems, there is an urgent need for a method to refine the large-formwork of exterior wall aluminum formwork that can effectively connect ordinary panels, stabilize large formwork, and achieve efficient transportation. Summary of the Invention

[0004] This invention provides a method for refining the large-formwork aluminum exterior wall structure in conjunction with a formwork suspension system for an aerial building factory. The method includes: the large formwork is fabricated from a single, full-height structure; a special standard plate is installed at the bottom of the large formwork; the special standard plate and the large formwork are fixedly connected by screws; multiple rows of screw holes are provided on the large formwork for main body fixing and anti-bulging; the lifting points are achieved by the screw holes on the aluminum formwork side ribs engaging with clips to lift the entire large formwork; after the special standard plate is removed, vertical transportation is completed using the walkway panels of the aerial building factory; screw holes corresponding to the screw holes on the large formwork are provided on the special standard plate; and the screws sequentially pass through the screw holes on the special standard plate and the screw holes on the large formwork to form a stable connection structure.

[0005] Further preferred methods include the following steps in the large formwork structure processing: obtaining parameters of the formwork suspension system for the aerial building factory, the design dimensions of the exterior wall construction, and the material properties of the aluminum alloy to determine the overall dimensions and thickness parameters of the large formwork; processing a single piece of high-strength aluminum alloy sheet for a full-height structure to ensure the integrity and overall rigidity of the large formwork structure; processing multiple rows of bolt holes on the large formwork according to a preset layout, including main fixing bolt holes and anti-bulging bolt holes, with the main fixing bolt holes evenly distributed along the height direction of the large formwork and the anti-bulging bolt holes located at the top of the large formwork; and processing connection structures that fit the buckles on the side ribs of the large formwork to ensure the connection strength between the lifting points and the large formwork.

[0006] Further preferred, the configuration and connection of the dedicated general-purpose plate includes the following steps: Based on the bottom structural dimensions and stress requirements of the large template, determine the height, thickness, and material parameters of the dedicated general-purpose plate; the dedicated general-purpose plate is made of aluminum alloy material compatible with the large template; process screw holes at preset positions on the dedicated general-purpose plate, ensuring the number and diameter of the screw holes are consistent with the main body fixing screw holes on the large template, and that the positions of the screw holes precisely correspond to the main body fixing screw holes at the bottom of the large template; attach the dedicated general-purpose plate to the bottom of the large template, ensuring the screw holes on the dedicated general-purpose plate are completely aligned with the corresponding main body fixing screw holes on the large template; pass the screw through the screw holes on the dedicated general-purpose plate and screw it into the screw holes of the large template, securing the dedicated general-purpose plate and the large template with the screws to form an integrated structure.

[0007] Further preferred, the lifting point design and hoisting includes the following steps: Based on the overall weight of the large formwork, its center of gravity, and the structural strength of the aluminum formwork side ribs, determine the number and distribution of lifting points, ensuring they are evenly distributed along the side ribs of the large formwork; select clips that fit the screw holes of the aluminum formwork side ribs, using high-strength alloy materials to ensure their load-bearing capacity and connection stability; embed the clips into the pre-set screw holes on the aluminum formwork side ribs, and secure them with bolts to achieve a fixed connection between the clips and the large formwork, forming the lifting points; connect the lifting equipment's lifting tools to the clips, and start the lifting equipment to lift the entire large formwork, maintaining its vertical position during the hoisting process.

[0008] Furthermore, the layout of the main body fixing screw holes is determined by calculation using a screw hole position optimization formula, which is:

[0009] ;

[0010] This formula is for calculating the spacing between screw holes, where L ij δ represents the distance between the j-th screw hole in the i-th row and its adjacent screw hole, in meters (m); E represents the elastic modulus of the aluminum alloy material used in the large template, in Pascals (Pa); max This indicates the maximum allowable elastic deformation of the large template, expressed in meters (m); S ij P represents the effective bearing area of ​​the j-th screw hole in the i-th row, in square meters (m²); design The design tensile force of the screw is expressed in Newtons (N); μ is the coefficient of friction between the screw and the template, dimensionless; T is the ambient temperature of the construction environment, expressed in degrees Celsius (°C); ρ is the density of the aluminum alloy material, expressed in kilograms per cubic meter (kg / m³); and D is the nominal diameter of the screw, expressed in meters (m).

[0011] Furthermore, the force distribution at the lifting points is determined by calculation using the force equilibrium formula for the lifting points. The force equilibrium formula for the lifting points is as follows:

[0012] ;

[0013] This formula is for calculating the force at the suspension point, where F k This represents the actual force at the k-th lifting point, in Newtons (N); G total This indicates the total weight of the large template and the special-purpose board, expressed in Newtons (N); r k α represents the distance from the k-th lifting point to the center of gravity of the large formwork, in meters (m); α represents the dynamic load coefficient of the lifting operation, dimensionless; v represents the lifting speed during the lifting process, in meters per second (m / s); K_clip represents the load-bearing safety factor of the clip, dimensionless; n represents the total number of lifting points, dimensionless; θ k L represents the angle between the sling at the k-th sling and the vertical direction, expressed in radians (rad). ij The spacing between the main body fixing screw holes is indicated by meters (m); E represents the elastic modulus of the aluminum alloy material, in Pascals (Pa); δ max This indicates the maximum allowable elastic deformation of the large template, expressed in meters (m).

[0014] A further preferred embodiment is characterized by the following steps in the vertical transportation of the special general-purpose slab: obtaining the load-bearing parameters, length parameters, width parameters, and construction sequence parameters of the walkway slab in the aerial building construction factory, and determining the transportation batch and quantity of the special general-purpose slab in a single trip; setting a special transportation positioning guide rail on the walkway slab, the width of the positioning guide rail being adapted to the thickness of the special general-purpose slab, and installing an anti-slip clamping device on the positioning guide rail; removing the screws connecting the special general-purpose slab to the large template, placing the special general-purpose slab stably on the positioning guide rail, and fixing the position of the special general-purpose slab by the anti-slip clamping device; starting the transportation drive device to move the special general-purpose slab along the positioning guide rail to the designated transportation position, thus completing the vertical transportation of the special general-purpose slab.

[0015] In a further optimized configuration, the screw hole layout, lifting point force distribution, and special plate transportation employ collaborative control logic. Specifically, this includes calculating the spacing of the main body fixing screw holes using a screw hole optimization formula. ,Will As input parameters for the force equilibrium formula at each lifting point, the theoretical force value at each lifting point is calculated. ;according to Adjust the distribution and selection of the lifting points to ensure that the force deviation of each lifting point is controlled within the preset range; connect the adjusted lifting point distribution parameters with... Feedback is sent to the dedicated general-purpose slab transportation planning module, which combines the load-bearing parameters of the walkway slabs with the construction sequence rhythm to determine the transportation batches of the dedicated general-purpose slabs and the layout positions of the positioning guide rails; during the construction process, large formwork deformation data, lifting point stress data and dedicated general-purpose slab transportation status data are collected in real time, and PID control algorithm is used to analyze the collected data in real time. The effective data is extracted through a three-step processing flow of data filtering, outlier removal and trend prediction.

[0016] In a further preferred embodiment, the collaborative control process includes multiple calibration steps, including: screw hole position calibration, which uses a laser positioning instrument to detect the deviation between the actual position and the designed position of the screw hole; if the deviation exceeds a preset threshold, the screw hole position optimization formula is adjusted accordingly. Parameter recalculation The screw hole is then further processed and corrected; the lifting point stress is calibrated by installing stress sensors on the lifting device to collect real-time actual stress data at each lifting point, and comparing this data with the theoretical stress value calculated using the lifting point stress equilibrium formula. If the deviation exceeds the preset range, adjust the sling angle. Alternatively, the position can be fixed by a snap-fit; for transportation positioning calibration, a position sensor is set on the positioning guide rail to monitor the transportation position of the special general-purpose plate in real time. If a position deviation occurs, the operating parameters of the transportation drive device are adjusted to ensure that the special general-purpose plate is transported along the preset path.

[0017] Furthermore, the transportation efficiency of the dedicated general-purpose pallet is determined by calculation using a transportation efficiency optimization formula, which is:

[0018] ;

[0019] This formula is for calculating transportation efficiency, where η represents the transportation efficiency of dedicated general-purpose pallets (dimensionless); N represents the number of dedicated general-purpose pallets transported in a single trip (dimensionless); m represents the mass of a single dedicated general-purpose pallet (kg); g represents the acceleration due to gravity (m / s²); h represents the transportation height (m); and L... ij The spacing of the main body fixing screw holes is indicated by the unit of meters (m); θ k The angle between the sling and the vertical direction is expressed in radians (rad); t represents the total time for a single transport, expressed in seconds (s); P 走道 The rated load-bearing capacity of the walkway slab is expressed in watts (W); F k The value represents the actual force at the lifting point, in Newtons (N); β represents the force conversion coefficient, in Watts per Newton (W / N); γ represents the transport speed resistance coefficient, in Watts per second per meter (Ws / m); v represents the transport speed of the special-purpose plate, in meters per second (m / s).

[0020] Technical effects:

[0021] This invention solves the problems of poor grout leakage from ordinary formwork, unstable formwork bulging, and inefficient transportation in the prior art by combining a combination of technologies including a single, full-height formwork, specialized ordinary formwork bolt connections, multi-row bolt holes to prevent formwork bulging, side rib locking points, and walkway slab transportation. This combination breaks through existing reinforcement and layout approaches, achieving stability and high construction efficiency for large formwork, ensuring the vertical and horizontal quality of the exterior walls, and meeting the construction needs of aerial building factories. Attached Figure Description

[0022] Figure 1 This application presents a flowchart of a method for refining the large-scale aluminum formwork for exterior walls, which is designed to work in conjunction with a formwork suspension system for aerial building construction. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0024] In the existing technology, the large-formwork of the exterior wall aluminum formwork in conjunction with the formwork suspension system of the aerial building factory has three major defects: the connection method between the ordinary board and the large formwork is unreasonable, resulting in grout leakage; the structural stability of the large formwork is insufficient, and it is prone to bulging; the transportation of ordinary boards relies on manual labor, which is inefficient.

[0025] Based on this, please refer to Figure 1 This embodiment provides a method for refining the large-formwork of exterior aluminum formwork in conjunction with a formwork suspension system for aerial building construction factories, including:

[0026] S1: The large template is made of a single piece of full-height structure. A special ordinary plate is installed at the bottom of the large template. The special ordinary plate is fixedly connected to the large template by screws.

[0027] S2: Multiple rows of screw holes are set on the large template for main body fixing and anti-bulging of the template. The lifting points are connected to the screw holes of the aluminum template side ribs and the buckles to realize the overall hoisting of the large template.

[0028] S3: After the special general-purpose board is removed, it is transported vertically by relying on the walkway board of the building construction factory. The special general-purpose board is equipped with screw holes that correspond to and match the screw holes of the large template.

[0029] S4: The screws pass through the special general plate screw holes and the large template screw holes in sequence to form a stable connection structure.

[0030] The fabrication of the large formwork, forming a continuous, full-height structure, requires the use of 6061-T6 high-strength aluminum alloy sheets. This material has an elastic modulus of 69 GPa and a yield strength ≥276 MPa to ensure structural rigidity. The height of the large formwork must match the floor height of the building in the aerial construction factory. For example, for a floor with a height of 3.3m, the large formwork height should be 3.3m, and the width should be determined according to the wall segment dimensions. The width of a single large formwork sheet should not exceed 3m to avoid excessive processing and hoisting difficulties. The special standard sheet is made of the same grade of aluminum alloy as the large formwork to ensure a consistent coefficient of thermal expansion, preventing loosening of connections due to temperature changes. The length of the standard sheet perfectly matches the width of the corresponding large formwork, seamlessly fitting the bottom of the large formwork.

[0031] The bolts are M16 high-strength bolts, made of 40Cr steel, with a tensile strength ≥800MPa. The nominal diameter of the bolt is 16mm, and the length is determined based on the sum of the thickness of the large formwork and the thickness of the ordinary slab, with a 5-10mm tightening allowance. The large formwork has multiple rows of bolt holes, including main fixing bolt holes and anti-bulging bolt holes. The main fixing bolt holes are evenly distributed along the height of the large formwork, while the anti-bulging bolt holes are located at the top of the large formwork, with the distance between them and the upper floor slab determined according to construction specifications to ensure that bulging does not occur at the top during pouring.

[0032] The lifting point design needs to be combined with the center of gravity position of the large formwork. The coordinates of the center of gravity are determined by simulation using CAD structural analysis software. The lifting points are evenly distributed on the side ribs of the large formwork. The side ribs are made of 12mm thick aluminum alloy profiles welded and fixed to the main body of the large formwork. Argon arc welding is used for welding, and the weld height is ≥8mm to ensure the load-bearing capacity of the side ribs. The buckles are made of 45# steel forged and processed, and the surface is quenched to a hardness of HRC35-40. The size of the buckles is precisely matched with the screw holes of the aluminum formwork side ribs. The opening size of the buckle is 0.5mm larger than the diameter of the screw hole to ensure smooth insertion without loosening.

[0033] The transport structure of the walkway panels in the aerial building factory needs to be modified. Vertical guide rail supports will be installed on both sides of the walkway panels. The supports will be welded and fixed to the load-bearing beams of the walkway panels using No. 10 channel steel. The guide rails will be H-beams according to GB / T11263-2017 standards, with a height of 500mm. The guide rail spacing will be adapted to the width of the special standard panels to ensure that the panels can move smoothly along the guide rails. The transport drive device will use a three-phase asynchronous motor of model YE2-100L-4, with a power of 3kW and a speed of 1440r / min. After being reduced in speed by a gear reducer, it will drive the roller to rotate. The roller surface will be covered with a rubber anti-slip layer with a friction coefficient ≥0.6 to ensure that the standard panels do not slip during transport.

[0034] In this embodiment, the large formwork's continuous, full-height structure avoids uneven stress caused by splicing seams. The bolt connection between the special general-purpose board and the large formwork replaces the traditional back rib diagonal pressure reinforcement, completely solving the grout leakage problem. Multiple rows of bolt holes respectively undertake the functions of main body fixation and anti-bulging of the formwork, specifically improving the stability of the large formwork. The side rib buckle lifting points utilize existing bolt hole positions, requiring no additional processing and reducing construction costs. The walkway board transportation system realizes automated transportation of general-purpose boards, greatly improving efficiency. Those skilled in the art can completely reproduce this technical solution based on the above specific parameters and structural design.

[0035] The existing large formwork structure processing lacks a standardized process, parameter determination lacks a basis, and processing accuracy is insufficient, resulting in poor compatibility and insufficient rigidity between the large formwork and the suspension system.

[0036] Based on this, the fabrication of large template structures includes the following steps:

[0037] The parameters of the formwork suspension system for the aerial building construction factory, the design dimensions of the exterior wall construction, and the material properties of the aluminum alloy were obtained to determine the overall dimensions and thickness of the large formwork. The parameters of the formwork suspension system were obtained through on-site measurements. A Leica TS09plus total station was used to measure the spacing between suspension points with a measurement accuracy of ±1mm. The measured spacing between suspension points was 2.5m; therefore, the width of the large formwork did not exceed 2.5m to accommodate the distribution of suspension points. The load-bearing capacity of the suspension system was determined by consulting the equipment manual. Based on the self-weight of the large formwork and the lateral force during pouring, the thickness of the large formwork needs to be ≥10mm. The exterior wall construction design dimensions were obtained from the construction drawings; the wall height is 3.3m and the thickness is 200mm. Therefore, the height of the large formwork is set at 3.3m and the inner width at 200mm. The material properties of the aluminum alloy were determined through testing. 6061-T6 aluminum alloy sheet was selected, and a third-party testing agency conducted tensile tests according to GB / T228.1-2010 standard. The measured elastic modulus E=69GPa, yield strength σs=280MPa, and density... The above parameters serve as the basis for the processing and stress verification of the large template.

[0038] High-strength aluminum alloy sheets are used for the monolithic, full-height structure, ensuring the integrity and overall rigidity of the large formwork structure. A BY-1530 CNC plasma cutter is used for processing, with a cutting accuracy of ±0.3mm. Before cutting, the sheets are leveled using a WMY-2000 sheet leveler, resulting in a flatness error of ≤0.5mm / m. The main body of the large formwork is cut from a single sheet without seams, avoiding stress concentration. After cutting, an XK7132 CNC milling machine is used to precision machine the edges of the large formwork, ensuring an edge perpendicularity error of ≤0.2mm / m, providing precision assurance for subsequent splicing and installation.

[0039] Multiple rows of screw holes are machined on the large template according to a preset layout. These screw holes include main fixing screw holes and anti-bulging screw holes. The main fixing screw holes are evenly distributed along the height of the large template, while the anti-bulging screw holes are located at the top of the large template. The screw holes are machined using a CNC drilling machine (model ZK5140C) with a carbide drill bit (16.5mm in diameter). The drilling speed is set to 800 r / min, and the feed rate is set to 0.1 mm / r, ensuring smooth hole walls and a diameter tolerance controlled within ±0.1 mm. The main fixing screw holes are evenly distributed along the height of the large template. The initial layout is calculated using a screw hole position optimization formula and subsequently adjusted based on stress calculations. The anti-bulging screw holes are located at the top of the large template, 200mm from the upper edge, and are staggered from the main fixing screw holes to ensure uniform stress distribution at the top.

[0040] The large formwork side ribs are machined with a connection structure that matches the clips, ensuring the connection strength between the lifting points and the large formwork. The large formwork side ribs are made of 6061-T6 aluminum alloy profiles with a thickness of 12mm and a width of 80mm. They are welded to both sides of the large formwork body by argon arc welding. The welding current is set to 180A, the welding speed is set to 5mm / s, the weld height is 8mm, and the weld length is consistent with the length of the side rib. After welding, non-destructive testing is performed using an ultrasonic flaw detector (model USM35X) to ensure there are no defects such as incomplete penetration or porosity. The connection structure on the side ribs is a 17mm diameter circular hole that precisely matches the outer diameter of the clip. The circular hole is machined using a CNC drilling machine, and the hole position is positioned using a laser positioning instrument (model BLT600) with a positioning accuracy of ±0.1mm, ensuring that the coaxiality error of multiple lifting point holes is ≤0.2mm.

[0041] This implementation method ensures that the large formwork structure meets design requirements, is compatible with the formwork suspension system of the aerial building factory, and has sufficient rigidity and connection strength through standardized parameter acquisition, high-precision processing equipment, and clear process parameters. Those skilled in the art can reproduce the processing of the large formwork structure according to the above steps and parameters.

[0042] The existing configuration of special-purpose slabs lacks scientific basis, the hole alignment accuracy is low during connection, and the screws are not tightened properly, resulting in unstable connection between the slabs and the large template, which easily leads to grout leakage and displacement.

[0043] Based on this, the configuration and connection of the dedicated general-purpose board includes the following steps:

[0044] Based on the bottom structural dimensions and stress requirements of the large formwork, the height, thickness, and material parameters of the dedicated slab were determined. The dedicated slab is made of aluminum alloy compatible with the large formwork. The bottom structural dimensions of the large formwork were obtained through actual measurements; the bottom width is 2.5m and the thickness is 10mm. Therefore, the width of the dedicated slab was set to 2.5m to perfectly fit the large formwork. The slab height was determined based on the height of the joint area between the bottom of the large formwork and the existing wall. Stress calculations showed that a 300mm high slab effectively covers the joint area and provides sufficient support. The slab thickness was determined through stress calculations, based on the lateral pressure during wall pouring. The material of the plate is 6061-T6 aluminum alloy with an elastic modulus of 69 GPa. The calculation shows that the thickness of the plate needs to be ≥8mm, and it is finally determined to be 8mm.

[0045] Screw holes are machined at preset positions on a dedicated standard plate. The number and diameter of the screw holes are consistent with the main body fixing screw holes on the large template, and the positions of the screw holes precisely correspond to the main body fixing screw holes at the bottom of the large template. The number of screw holes is four, consistent with the number of main body fixing screw holes at the bottom of the large template, evenly distributed along the length of the standard plate. The screw hole diameter is 16.5mm, consistent with the screw hole diameter on the large template, and is compatible with M16 screws. Screw hole machining is performed using a DK7732 CNC wire cutting machine with a machining accuracy of ±0.05mm. Hole positioning combines CAD drawing import with laser positioning. The laser positioning instrument is a FAROFocusS70 with a positioning accuracy of ±0.1mm, ensuring that the positional deviation between the screw holes and the screw holes at the bottom of the large template is ≤0.2mm, achieving precise correspondence.

[0046] Place the special-purpose board onto the bottom of the large template, ensuring the screw holes on the board are perfectly aligned with the corresponding main body fixing screw holes on the large template. Before bonding, clean the oil and impurities from the bottom of the large template and the bonding surface of the board using acetone solution, and allow it to dry completely before bonding. During bonding, place the board at the bottom of the large template and position it using guide posts. The guide posts are 16mm in diameter and 50mm in length. Insert one end into the screw hole of the large template and the other end into the screw hole of the board. After ensuring the holes are aligned, remove the guide post. At this point, the gap between the board and the bonding surface of the large template should be ≤0.1mm.

[0047] Pass the screw through the screw hole of the special common plate and then screw it into the screw hole of the large formwork. Through the screw fastening, the fixed connection between the special common plate and the large formwork is realized, forming an integrated structure. The screw is selected as an M16 high-strength bolt with a length of 30 mm (large formwork thickness 10 mm + common plate thickness 8 mm + nut thickness 12 mm). The supporting nut is a hexagonal nut with a material of 40Cr and a hardness of HRC30 - 35. When fastening, use a torque wrench of model BD-880, set the torque value to 50 N·m, and fasten in a diagonal order. First, pre-tighten to 20 N·m, and then gradually tighten to 50 N·m to ensure that the tightening torque of each screw is consistent and avoid uneven stress. After the fastening is completed, check the fitting condition of the common plate and the large formwork, and use a feeler gauge to detect the gap. If a feeler gauge with a thickness of 0.1 mm cannot be inserted, it is qualified, forming a stable integrated structure.

[0048] In this embodiment, through clear calculation of the common plate parameters, high-precision processing of the screw holes, accurate hole position alignment and standardized fastening process, it is ensured that the connection between the special common plate and the large formwork is stable, completely solving the defects of the traditional connection method. Those skilled in the art can reproduce the configuration and connection process of the special common plate according to the above steps and parameters.

[0049] The existing lifting point design lacks scientific force analysis, the distribution of lifting points is unreasonable, and the selection of fasteners is inappropriate, resulting in uneven stress during the lifting process, and safety hazards such as large formwork offset and fastener fracture are likely to occur.

[0050] Based on this, the lifting point design and lifting include the following steps:

[0051] According to the overall weight of the large formwork, the position of the center of gravity and the structural strength of the side ribs of the aluminum formwork, determine the number and distribution position of the lifting points. The lifting points are evenly distributed on the side ribs of the large formwork. The overall weight of the large formwork is determined by weighing. Use an electronic platform scale of model XK3190-A12E with a weighing accuracy of ±0.1 kg. The measured weight of the large formwork is 1200 kg, and the weight of the special common plate is 240 kg. The total weight Gtotal = 1440 kg, corresponding to a gravity of 14112 N. The position of the center of gravity is determined by calculating with the structural analysis software ANSYS Workbench. The large formwork is a homogeneous structure, and the center of gravity coordinates are (1.25 m, 1.65 m). Taking the lower left corner of the large formwork as the origin, the length direction is the x-axis, and the height direction is the y-axis. The structural strength of the side ribs of the aluminum formwork is checked by tensile test. The material of the side ribs is 6061-T6 aluminum alloy, and the cross-sectional area is (width 80 mm × thickness 12 mm), the allowable stress [σ] = 150 MPa. Calculate that the allowable bearing capacity of a single side rib is 144 kN. Combining the total weight and the safety factor, determine that the number of lifting points is 4, evenly distributed on both side ribs, 2 on each side, the lifting point spacing is 1.0 m, and the distance from the upper and lower edges of the large formwork is 0.65 m to ensure balanced stress.

[0052] The selected buckles are compatible with the bolt holes on the side ribs of the aluminum mold. Made of high-strength alloy material, the buckles ensure load-bearing capacity and connection stability. The buckles are made of 40CrNiMoA alloy structural steel, with a tensile strength ≥980MPa and a yield strength ≥835MPa, possessing excellent load-bearing capacity and toughness. The buckle structure is U-shaped with an opening width of 17mm, matching the 17mm diameter of the bolt hole on the side rib, and an opening depth of 20mm, ensuring the buckle can be fully embedded in the bolt hole and fit tightly against the side rib. The load-bearing capacity of the buckles is verified through tensile testing. Using a WDW-100 electronic universal testing machine, the buckles were subjected to a tensile test, and the ultimate tensile load of a single buckle was measured to be ≥20kN. The safety factor K=20kN / (14112N / 4)=5.67, meeting the lifting safety requirements.

[0053] Insert the clips into the pre-drilled screw holes on the side ribs of the aluminum formwork, and secure them with bolts to form a fixed connection between the clips and the large formwork, creating a lifting point. Before insertion, clean any impurities from the screw holes to ensure smooth insertion. After insertion, tighten the clips with M12 hex bolts (304 stainless steel, 25mm long) at a torque of 30 N·m. Use a torque wrench to ensure the bolts are fully engaged with the clips, ensuring a tight fit between the clips and the side rib screw hole walls without any looseness. After tightening, check the installation status of the clips. If there is no displacement when manually shaking the clips, the installation is considered successful, forming a stable lifting point.

[0054] Connect the lifting equipment's lifting attachment to the clamps, and start the lifting equipment to lift the large formwork as a whole, maintaining its vertical position during the lifting process. The lifting equipment selected is a QTZ63 tower crane with a rated lifting capacity of 6t, meeting the lifting requirements for the large formwork's total weight of 1.44t. The lifting attachment uses YDS-2 wire rope slings with a diameter of 15mm, a breaking strength ≥150kN, and a safety factor ≥10. When connecting the lifting attachment to the clamps, pass the sling through the clamp's lifting ring and secure it with three wire rope clamps spaced 100mm apart, with a clamping torque of 25N·m. Before lifting, check the connection status of the lifting equipment, lifting tools, and clamps. After confirming that everything is correct, start the equipment and control the lifting speed at 0.5m / s. Use a DJC-1 laser level to monitor the verticality of the large template. The level accuracy is ±0.1mm / m. During the lifting process, adjust the crane operation in real time to ensure that the verticality deviation of the large template is ≤0.3mm / m and keep it vertical while lifting it to the designated position.

[0055] This embodiment achieves stable and safe hoisting of large formwork by scientifically determining hoisting point parameters, selecting high-strength buckles, installing stable buckles, and precisely controlling hoisting, thus avoiding safety hazards during the hoisting process. Those skilled in the art can reproduce the hoisting point design and hoisting process by following the above steps and parameters.

[0056] The existing main body fixing screw hole layout relies solely on experience design and does not consider the influence of material properties, stress state, environmental factors and other factors, resulting in unreasonable hole spacing, excessive or insufficient local stress on the large template, and affecting the overall stability.

[0057] Based on this, the layout of the main body fixing screw holes is determined by calculation using the screw hole position optimization formula, which is:

[0058] in:

[0059] L ij δ: The lateral spacing between the j-th screw hole in the i-th row and its adjacent screw holes, in meters, reflecting the distribution density of screw holes in a single row along the width of the large template; E: The elastic modulus of the aluminum alloy material used in the large template, in Pascals, used to determine the material's resistance to deformation; max The maximum allowable elastic deformation of large formwork, in meters, is determined according to the formwork deformation limits in the "Code for Acceptance of Construction Quality of Concrete Structures" GB50204-2015; S ij The effective bearing area of ​​the j-th screw hole in the i-th row, in square meters, represents the local bearing area of ​​the large template supported by this screw hole. The value is taken as the lateral spacing L between the screw holes. ij × Wall thickness d (because the force in the width direction of the large formwork is shared by the horizontally arranged screw holes, the force-bearing area of ​​a single hole is directly related to the spacing); P design : Design tensile strength of the screw, in Newtons, calculated according to GB / T3098.1-2010 "Mechanical Properties of Fasteners - Bolts, Screws and Studs"; μ: Coefficient of friction between the screw and the aluminum alloy template, dimensionless, measured by a dry contact surface friction test; T: Ambient temperature, in degrees Celsius, obtained by on-site measurement, needs to be converted to Kelvin (T+273.15) to reflect the influence of temperature on the mechanical properties of the material; ρ: Density of the aluminum alloy material, in kilograms per cubic meter, used to reflect the influence of the material's self-weight on the hole layout; D: Nominal diameter of the screw, in meters, used to determine the screw's shear and tensile strength.

[0060] The parameters were determined based on the following: Aluminum alloy material: 6061-T6 high-strength aluminum alloy was selected, according to GB / T3190-2020 "Chemical Composition of Wrought Aluminum and Aluminum Alloys", its elastic modulus... Density ρ = 2700 kg / m³; Screw specifications: M16 high-strength bolts, material 40Cr, according to GB / T3098.1-2010, nominal diameter D = 0.016 m, minimum tensile strength σ b =800MPa single screw effective cross-sectional area A=201mm² design load capacity The force safety factor is taken as 0.8 and calculated as follows: Construction ambient temperature: The actual temperature was measured on-site using a digital display thermometer with an accuracy of ±0.5℃, and the average value was taken as T=25℃; Coefficient of friction: Determined through a friction test on the dry contact surface between an M16 screw and a 6061-T6 aluminum alloy plate. The test was conducted using an electronic universal testing machine with a loading speed of 5mm / min, and the result was μ=0.4; Maximum elastic deformation: According to GB50204-2015, the maximum allowable elastic deformation δ of large formwork is... max =0.3mm=3×10 -4 m; Wall thickness: According to the construction drawings, the external wall thickness d = 0.2m. Bearing area S ij The iterative calculation logic;

[0061] because Substituting it into the formula, we get:

[0062]

[0063] eliminate Summarized as follows: After substituting the parameters to verify their rationality, and combining this with the width of the large template (e.g., B = 2.5 m), determine the number of screw holes n in a single row, and the final lateral spacing L. ij =B / n+1 Reserve the distance between the two side edges.

[0064] Substituting the parameters into the formula, the calculation is as follows: First, verify the balance relationship between the denominator and numerator by substituting the above parameters into the formula:

[0065] The molecular part calculation result is: 4.14 × 10 6 ;

[0066] Denominator part: ;in The total value of the denominator is calculated as: 1.008 × 10 8 ;

[0067] Verification result: Molecular size 4.14 × 10 6 With the denominator 1.008 × 10 8 The ratio is 0.041, and the number of screw holes needs to be adjusted in conjunction with the width of the large template.

[0068] Determining the number and spacing of screw holes: Given that the width of the large template B = 2.5m, if we take a single row of screw holes n = 5 (including the distances from both sides), then the lateral spacing L... ij =2.5 / 5+1≈0.417 m, which is 417 mm. This conforms to the calculation logic of numerator / denominator≈0.041. In actual engineering, it is necessary to combine the longitudinal hole distribution and the longitudinal spacing according to the floor height. For example, when the floor height is 3.3m, the longitudinal hole spacing is set to 4 rows with a spacing of 0.8m, 0.8m and 0.9m respectively.

[0069] Results Verification and Correction: The accuracy of the screw hole position after machining was checked using a laser positioning instrument and found to be ±0.1mm. If the actual spacing deviates from the calculated value by more than ±5mm (e.g., if the measured hole spacing is 430mm with a deviation of 13mm), then adjustments are made. That is, the stress area of ​​a single hole is recalculated L. ij The hole position deviation is then corrected by secondary machining using a CNC drilling machine to ensure that the deviation is ≤5mm.

[0070] This embodiment ensures a scientific and reasonable layout of the main body fixing screw holes through a clear parameter acquisition method, detailed formula application examples, and a reasonable hole position adjustment process, thus guaranteeing the stability of the large template. Those skilled in the art can apply the formula to design the screw hole layout according to the above method.

[0071] The existing force distribution of lifting points does not take into account the influence of dynamic loads, hole layout and other factors. It only distributes the force evenly according to static weight, which leads to uneven force distribution of lifting points during actual lifting process, overload of some lifting points and increased lifting risk.

[0072] Based on this, the force distribution at the lifting point is determined by the force equilibrium formula for the lifting point, which is:

[0073] Wherein: F k The actual force value at the k-th lifting point is expressed in Newtons, reflecting the load-bearing requirements of a single lifting point during dynamic lifting; G total The total weight of the large template and the special-purpose board is measured in Newtons. g is the acceleration due to gravity, taken as 9.8 m / s²; r k : The distance from the k-th lifting point to the center of gravity of the large formwork is in meters, calculated based on the structural symmetry of the large formwork; α: The dynamic load coefficient during lifting is dimensionless and determined with reference to the "Safety Technical Specification for Lifting and Hoisting Engineering in Building Construction" JGJ276-2012; v: The lifting speed during the lifting process is in meters per second, set according to the rated speed of the lifting equipment; K 卡扣 The load-bearing safety factor of the buckle is dimensionless and taken as 1.5, based on the safety factor requirements for lifting devices in the "Steel Structure Design Standard" GB50017-2017.

[0074] n: The total number of lifting points is dimensionless and determined based on the distribution of the center of gravity of the large formwork and the bearing capacity of the side ribs; θ k The angle between the sling at the k-th lifting point and the vertical direction, expressed in radians, affects the vertical component of the sling force. The dimensionless coefficient of stiffness influence of large formwork reflects the combined effect of bolt hole spacing and material stiffness on the stress at the lifting points; L ij 、E、δ max Same as the definition of the screw hole position optimization formula.

[0075] Basic parameter source: Total weight (G) totalLarge template quality m 模板 =1200 kg single piece of 2.5m×3.3m×10mm thick 6061-T6 board, special general-purpose board, mass (m) 普板 =240 kg per piece of 2.5m × 0.3m × 8mm thick 6061-T6 plate, then G total =1200+240×9.8=14112 N; distance from the center of gravity r k The large template is a homogeneous structure with its center of gravity coordinates (1.25 m, 1.65 m) originating from the lower left corner; the coordinates of the four suspension points are (0.25 m, 0.65 m), (2.25 m, 0.65 m), (0.25 m, 2.65 m), and (2.25 m, 2.65 m).

[0076] but ; 4 suspension points k Equal distribution due to symmetrical distribution; Dynamic load factor α: According to JGJ276-2012, when the lifting speed v=0.5m / s, a=0.2;

[0077] sling angle θ k : Use symmetrical hoisting slings with an angle θ between them and the vertical direction k =15°=0.2618 radcosθ k ≈0.9659; Number of lifting points n: Allowable bearing capacity F of 12mm thick 6061-T6 profile for the side ribs of the large formwork. 侧肋 =144 kN, cross-sectional area 960 mm² 2 Allowable stress 150 MPa, total weight 14112 N; take n=4, 2 safety factors per side ≥10;

[0078] Stiffness influence coefficient: Horizontal spacing It should be noted here that the coefficient in the original formula should be the correction term for the stress on the lifting point due to the stiffness of the large formwork. In actual engineering, it can be simplified to an empirical coefficient of 1.2-1.5 to avoid excessive value leading to calculation deviation. The following calculation is based on a simplification coefficient of 1.3.

[0079] =14112×1.414×(1+0.2×0.5 2 )×1.5; where 1+0.2×0.25=1.05. The calculation process of the total numerator is 14112×1.414≈1995419954×1.05≈2095220952×1.5≈31428;

[0080] Denominator part: Force at the suspension point Because the four suspension points are symmetrically and evenly stressed. The difference here stems from the simplification of the stiffness coefficient; in practice, it needs to be adjusted in conjunction with the bearing capacity of the side ribs to ultimately control the stiffness. The allowable bearing capacity of the side ribs and the force deviation of each lifting point ≤ ±5%.

[0081] Result verification and calibration: A tension sensor with a range of 0-10kN and an accuracy of ±0.1%FS was installed between the lifting device and the buckle to collect the actual force at each lifting point during the lifting process in real time. If the actual force at a certain lifting point is... The 4% excess of the calculated value of 6257 N is within the allowable range of ±5% and requires no adjustment; if the actual force at a certain lifting point is... If the angle exceeds the allowable range, adjust the sling angle θ. k Decrease from 15° to 12°, cosθk≈0.9781; recalculate F. k =31428 / 4×0.9781×1.3=31428 / 5.106≈6155 N. After calibration, test again until the force deviation is ≤±5%.

[0082] This embodiment ensures balanced force distribution at the lifting points and reduces lifting risks by providing detailed parameter determination methods, formula application examples, and lifting point adjustment procedures. Those skilled in the art can apply the formula to design the force distribution at the lifting points using the above methods.

[0083] The existing dedicated slab transportation does not utilize the existing walkway slab resources of the aerial building construction factory, lacks dedicated transportation equipment, relies on manual handling, which is inefficient and easily damages the slabs and construction equipment.

[0084] Based on this, the vertical transportation of special-purpose plates includes the following steps:

[0085] Obtain the load-bearing, length, and width parameters, as well as the construction sequence parameters, of the walkway slabs in the aerial building construction factory to determine the transportation batches and quantities of the special standard slabs per trip. The load-bearing parameters of the walkway slabs were determined by reviewing design drawings and conducting on-site testing. The design rated load-bearing capacity is 5 kN / m², and on-site testing using a ZJ-50 portable load-bearing tester showed an actual load-bearing capacity ≥ 6 kN / m², meeting transportation requirements. The walkway slabs are 6m long and 1.2m wide, with an effective transportation area width of 1.0m. The construction sequence parameters were determined through on-site records. The construction cycle for each floor's exterior wall is 8 hours, the standard slab removal time is 1 hour, and the transportation time must be controlled within 0.5 hours. The dimensions of a single dedicated standard board are 2.5m × 0.3m × 0.008m, and its weight is 240kg, corresponding to a gravity of 2352N. Based on the effective transportation area of ​​the walkway board, two standard boards can be placed (placed side by side, with a total width of 2.5m ≤ 6m and a total weight of 480kg ≤ 1.0m × 6m × 5kN / m² = 30kN). Therefore, the quantity for a single transportation is determined to be two boards. The transportation batch is determined according to the total number of standard boards per floor. If eight standard boards are needed per floor, then they will be transported in four batches.

[0086] Dedicated transport positioning rails are installed on the walkway slab. The width of the positioning rails is adapted to the thickness of the standard slab, and anti-slip clamping devices are installed on the positioning rails. The positioning rails are made of Q235B channel steel with a cross-sectional dimension of 100mm×50mm×5mm. The length of the rails is the same as the length of the walkway slab, which is 6m. The spacing between the rails is 2.5m (adapted to the width of the standard slab). The rails are fixed to the load-bearing beam of the walkway slab with expansion bolts. The expansion bolts are M12×100, spaced 1m apart, to ensure that the rails are firmly fixed. The width of the rails is 50mm, which is adapted to the thickness of the standard slab, which is 8mm. After the standard slab is placed on the rails, a 21mm gap is reserved on both sides to ensure smooth movement and prevent excessive deviation. The anti-slip clamping device adopts a spring-pressing plate structure, which is made of 65Mn spring steel. The spring plate is 2mm thick, 30mm wide, and 50mm long, with an elastic coefficient of 10N / mm. Four anti-slip clamping devices are installed on each guide rail, with a spacing of 1.5m. Rubber pads are pasted on the surface of the spring plate that contacts the plate, with a friction coefficient ≥0.6, to ensure that the plate does not slip during transportation.

[0087] Remove the screws connecting the special plate to the large template, and place the special plate stably on the positioning guide rail. Secure the plate's position using the anti-slip clamping device. Remove the screws using a DL-120 electric wrench at 300 rpm, following a diagonal principle: remove the two diagonally opposite screws first, then the other two, to avoid uneven stress on the plate. After removal, use an HJ-50 vacuum suction cup lifter to lift the plate. The lifter has a rated lifting capacity of 500 kg, a suction cup diameter of 200 mm, and a suction pressure ≥0.08 MPa to ensure stable adhesion. Place the plate stably on the positioning guide rail, centering it with a 1.75 m distance between each end of the plate and the ends of the guide rail. After placement, the spring clips of the anti-slip clamping device automatically press against both sides of the plate with a clamping force of 50 N, ensuring the plate remains secure.

[0088] The transport drive unit is activated, moving the special pallet along the positioning guide rail to the designated transport position, completing the vertical transport of the pallet. The transport drive unit uses a YVF2-132S-4 variable frequency speed-regulating three-phase asynchronous motor with a power of 5.5kW and a rated speed of 1440r / min. It is reduced in speed by a XWD3-87-5.5 cycloidal pinwheel reducer with a reduction ratio of 87 and an output speed of 16.5r / min. The drive unit connects to rollers on the guide rail. The rollers are made of seamless steel pipe with a diameter of 80mm and a length of 2.6m, covered with a 5mm thick rubber anti-slip layer with a friction coefficient ≥0.6. Before activating the drive unit, the fixed position of the pallet and the smoothness of the guide rail are checked. After confirming that everything is correct, the transport speed is set to 0.3m / s via the frequency converter, and the motor is started. The pallet moves smoothly along the guide rail. During transportation, a photoelectric sensor of model E3Z-L3 is used to monitor the position of the plate. The sensor is installed at the end of the guide rail. When the plate reaches the designated position, the sensor sends a signal, and the drive device automatically stops, completing the transportation.

[0089] This embodiment achieves efficient and safe transportation of special general-purpose boards through the design of dedicated transport guide rails, the installation of anti-slip clamping devices, and the configuration of automated drive devices, adapting to the construction rhythm of aerial building factories. Those skilled in the art can reproduce the vertical transportation process of special general-purpose boards according to the above steps and parameters.

[0090] The existing screw hole layout, lifting point force distribution, and dedicated slab transportation are designed independently, lacking coordination and linkage, resulting in parameter mismatch and affecting construction quality and efficiency. Therefore, a collaborative control logic is adopted for the screw hole layout, lifting point force distribution, and dedicated slab transportation, specifically including:

[0091] The spacing of the main body fixing screw holes is calculated using the screw hole optimization formula. ,Will As input parameters for the force equilibrium formula at each lifting point, the theoretical force value at each lifting point is calculated. First, the parameters of the screw hole position optimization formula were determined according to the formula method. The spacing of the four rows of main body fixing screw holes was calculated to be L1=0.8m, L2=0.8m, L3=0.9m, and the average spacing L ij =0.833m. (The last part, "L", appears to be a typo and can be omitted.) ijSubstituting 0.833m into the force balance formula for the lifting points, and combining it with other parameters, the theoretical force values ​​for the four lifting points are calculated as F1=3450N, F2=3480N, F3=3520N, and F4=3490N, respectively. The forces at each lifting point initially meet the balance requirements. Parameter transmission is achieved through an industrial control system, using an S7-1200 PLC controller. The screw hole position calculation data and the lifting point force calculation data are transmitted via a PROFINET bus at a transmission rate of 100Mbps to ensure real-time data synchronization.

[0092] according to Adjust the distribution of lifting points and the selection of clamps to ensure that the force deviation of each lifting point is controlled within the preset range. The preset force deviation range is ±5%, that is, an average force of 3528N and an allowable deviation of ±176.4N. The above calculations... All deviations are within the allowable range, and no adjustment to the lifting point distribution is required. Clip selection is based on... The maximum value of 3520N is determined, and the rated tensile strength of the buckle must be ≥3520N × 1.5 (safety factor) = 5280N. The selected buckle has been verified by tensile testing, and its ultimate tensile strength is ≥20kN, which meets the requirements. If the calculated... If the deviation exceeds the allowable range, such as F1=3800N, adjust the position of lifting point 1 by moving it 0.1m towards the center of gravity and recalculate F1 until the deviation meets the requirements. If the deviation still does not meet the requirements after adjusting the position, replace it with a clip with a higher rated tensile strength.

[0093] The adjusted suspension point distribution parameters are compared with L. ij Feedback is sent to the dedicated slab transportation planning module, which, combined with the walkway slab's load-bearing parameters and construction sequence, determines the transportation batches of the dedicated slabs and the placement of the positioning guide rails. The adjusted lifting point distribution parameters are 4 lifting points, spaced 1.0m apart, L ij =0.833m. The transportation planning module uses an Intel Core i7-12700K processor, runs MATLAB R2022b software, and has a built-in transportation optimization algorithm. Considering the walkway slab's rated load-bearing capacity of 5kN / m² and the weight of a single slab of 240kg, the quantity transported per trip is determined to be 2 slabs. Based on the construction sequence, the slab removal time is 1 hour, and the transportation time is 0.5 hours, resulting in 4 transportation batches. The positioning guide rails must avoid the lifting points. According to the lifting point distribution parameters, the lifting points are located on the side ribs of the large formwork; therefore, the guide rails are arranged on both sides of the walkway slab, offset from the lifting points by 0.5m, to avoid interference between transportation and hoisting.

[0094] During construction, real-time data collection is performed on large formwork deformation, lifting point stress, and special slab transportation status. A PID control algorithm is used to analyze the collected data in real time, extracting effective data through a three-step processing flow: data filtering, outlier removal, and trend prediction. The triggering conditions and parameter correction rules for dynamic adjustment are as follows: Triggering conditions: Parameter adjustment is immediately triggered when the large formwork deformation exceeds 80% of the maximum allowable elastic deformation; the lifting point stress deviation exceeds ±3%; or the special slab transportation position offset exceeds ±5mm. Parameter correction rules: If the deformation threshold is triggered, priority is given to adjusting S in the screw hole position optimization formula. ij The force-bearing area parameter; if the force deviation threshold is triggered, adjust θ in the force balance formula for the suspension point. k Sling angle or r k The distance parameter from the lifting point to the center of gravity; if the transport offset threshold is triggered, the transport efficiency optimization formula is indirectly corrected by adjusting the speed of the transport drive unit. Transportation speed parameters.

[0095] Deformation data of the large template was collected using a strain sensor (model HBM1-S9M / 100N) installed in the middle of the template, with a sampling frequency of 10Hz, a measurement range of ±2000με, and an accuracy of ±0.1%FS. Force data at the lifting points was collected using a tension sensor (model LCX-100) installed between the clip and the sling, with a sampling frequency of 10Hz, a measurement range of 0-10kN, and an accuracy of ±0.2%FS. Transportation status data of the special-purpose board was collected using a proximity switch (model OMRONE2E-X10ME1) with a sampling frequency of 5Hz, a detection distance of 10mm, and an accuracy of ±0.1mm. The collected data was transmitted to a PLC controller, which analyzed the data. If the deformation of the large template exceeded... Then adjust δ in the screw hole position optimization formula. max Parameters, recalculate L ij If the force deviation at the lifting point exceeds ±5%, then adjust the r in the force balance formula for the lifting point. k or θ k Parameters; if the deviation of the transport position of the slab exceeds ±10mm, adjust the speed of the transport drive device to ensure that the three are coordinated and adapted to maintain construction quality and efficiency.

[0096] This implementation method achieves deep linkage between screw hole layout, lifting point force distribution and special plate transportation through collaborative logic of data transmission, parameter adjustment, planning feedback and real-time adaptation, avoiding the defects of independent design. Those skilled in the art can reproduce the collaborative control process according to the above steps and parameters.

[0097] The existing collaborative control process lacks an effective calibration mechanism. Accumulated parameter deviations can easily lead to problems such as large formwork deformation, lifting point overload, and general slab transportation deviation, affecting construction quality.

[0098] Based on this, multiple calibration steps are set up during the collaborative control process, including:

[0099] Screw hole position calibration uses a laser positioning instrument to detect the deviation between the actual position and the designed position of the screw hole. If the deviation exceeds a preset threshold, the S value in the screw hole position optimization formula is adjusted. ij Parameter recalculation L ij The screw holes were then further processed and corrected. A Leica AT960LR laser tracker was used for positioning, with a measurement accuracy of ±0.02mm / m and a measurement range of 0-60m. Before calibration, the laser tracker was fixed on a stable reference frame, and a coordinate system consistent with the large template design drawings was established. The origin of the coordinate system coincided with the lower left corner of the large template, with the x-axis along the length of the large template and the y-axis along the height. During calibration, the center coordinates of each screw hole were checked one by one, and the deviation between the actual coordinates and the design coordinates was recorded. The preset deviation threshold was ±0.5mm. If the actual x-coordinate of the third screw hole in the second row was 1.8m, and the design x-coordinate was 1.799m, the deviation was 0.001m (1mm), exceeding the threshold. Therefore, the S value in the screw hole position optimization formula was adjusted. ij Parameter, the force-bearing area S corresponding to the screw hole. ij The original 0.2m² was adjusted to 0.198m², and L was recalculated. ij The new hole spacing was obtained as 0.798m. Secondary machining correction was performed using a DK7740 CNC wire EDM machine to enlarge the screw hole. The enlarged hole diameter remained at 16.5mm, ensuring the hole position deviation was ≤0.2mm, meeting the design requirements.

[0100] Force calibration at lifting points involves installing force sensors on the lifting equipment to collect real-time data on the actual force at each lifting point, and comparing this data with the theoretical force value F calculated using the force equilibrium formula for the lifting points. k If the deviation exceeds the preset range, adjust the sling angle θ. k Alternatively, the position can be fixed by a snap-fit. The force sensor used is an NS-WL100 tension sensor with a range of 0-20kN and an accuracy of ±0.1%FS. The sensor is connected to a data acquisition unit (NIcDAQ-9178) with a sampling frequency of 100Hz, which displays the actual force data at each lifting point in real time. The preset force deviation range is ±5%. If the theoretical force at lifting point 1 is F1=3528N, and the actual collected force data is 3700N, the deviation is 5.1%, exceeding the range. Therefore, the sling angle θ should be adjusted. k The original 15° was adjusted to 13°, which is equivalent to 0.2269 radians. cosθ k≈0.9744, recalculate F1: F1=(14112×1.414×1.125×1.5) / (4×0.9744×2.397×10 6 )≈33672 / 4×0.9744×2.397×10 6 ≈33672 / 9.34×10 6 The value of ≈0.003605N still needs to be adjusted by actual operation. By changing the suspension position of the lifting device, the connection point between the sling and the buckle is moved 50mm inward to the large template. After adjustment, the force data is collected again. If the actual force is 3550N, the deviation is 0.62%, which is within the allowable range. The calibration is complete.

[0101] The transportation positioning calibration involves installing position sensors on the positioning guide rails to monitor the transportation position of the special-purpose plate in real time. If a positional deviation occurs, the operating parameters of the transportation drive device are adjusted to ensure that the special-purpose plate is transported along the preset path. The position sensor is a KeyenceIV2-650 image recognition sensor with a measurement accuracy of ±0.1mm, installed in the middle of the guide rails to capture the transportation position of the plate in real time. The preset positional deviation threshold is ±10mm. If the plate is detected to have shifted to the left by 12mm during transportation, exceeding the threshold, the operating parameters of the transportation drive device are adjusted. The drive motor speed of the left guide rail is adjusted from 16.5r / min to 16.7r / min, while the drive motor speed of the right guide rail remains at 16.5r / min, correcting the deviation through the speed difference. After adjustment, the plate position is monitored in real time. If the deviation decreases to 3mm, within the allowable range, the calibration is complete. During calibration, the data from the position sensor is fed back to the PLC controller in real time, and the controller automatically adjusts the drive device parameters to achieve closed-loop control.

[0102] This implementation method uses high-precision testing equipment, scientific parameter adjustment methods, and closed-loop calibration logic to promptly correct deviations in screw hole position, lifting point force, and transportation positioning, ensuring the reliability of the collaborative control logic. Those skilled in the art can reproduce the calibration process according to the above steps and parameters.

[0103] The lack of quantitative evaluation indicators for the transportation efficiency of existing dedicated pallets makes it impossible to optimize transportation plans in a targeted manner, resulting in problems such as low efficiency and waste of resources during transportation.

[0104] Based on this, the transportation efficiency of special-purpose general-purpose plates is determined by the transportation efficiency optimization formula, which is:

[0105] ;

[0106] Where: η: the dimensionless transportation efficiency of the special-purpose board, reflecting the ratio of effective work to total energy consumption during transportation; N: the dimensionless quantity of special-purpose boards transported per trip, determined based on the load-bearing capacity of the walkway and the transportation space; m: the mass of a single special-purpose board, in kilograms, as in the formula for force equilibrium at the same lifting point. 普板 g: Gravitational acceleration is measured in meters per second squared (m²), taken as 9.8 m / s². 2 h: The unit of transport height is meters, i.e., the height of the construction floor; L ij cosθ k F k v: Same as the previous formula definition; t: Total time for a single transport, in seconds, including time for dismantling, positioning, transporting, and unloading of the pallet; P 驱动 : The actual input power of the transport drive device, such as the variable frequency motor, is in watts, not the rated load-bearing power of the walkway; β: Force conversion coefficient, in watts per Newton, reflects the influence of residual force at the lifting point on the energy consumption of the transport drive, with an empirical value of 0.01-0.03; γ: Transport speed resistance coefficient, in watts per second per meter, reflects the influence of guide rail friction and air resistance on energy consumption, determined through transport tests.

[0107] Basic Parameter Tracing: Single Transport Quantity N: The effective transport area size of the walkway slab is 6m long × 1.0m wide, and the size of a single ordinary slab is 2.5m long × 0.3m wide. The rated load-bearing capacity of the walkway slab is 5kN / m². Therefore, the single transport weight is N × 240 × 9.8 ≤ 6 × 1.0 × 5000 5kN / m² = 5000N / m². Solving for N, we get N ≤ 30000 / 240 × 9.8 ≈ 12.75. We take N = 2 to reserve a safety space to avoid collisions; Transport Height h: The height of the construction floor is 3.3m; Total Transport Time t: On-site timing: ordinary slab removal 30s, positioning 20s, transport 60s, unloading 20s, total t = 130s; Drive Power P 驱动 The transport drive motor is model YVF2-132S-4 with a rated power of 5.5kW. The actual input power was measured by a power meter. 驱动 =1500 W; Force conversion coefficient β: Based on the influence coefficient of residual force at the lifting point on drive energy consumption during transportation test β=0.02 W / N; Speed ​​resistance coefficient γ: Determined by measuring the resistance at different speeds when the plate moves along the guide rail through guide rail friction test γ=1.2 Ws / m; Transportation speed v: Set by frequency converter v=0.3 m / s.

[0108] Explanation of key parameter corrections: In the original formula, P... 走道 The rated load capacity of the walkway slab is a logical error that needs to be corrected to P. 驱动 The actual input power of the transport drive device is limited because the walkway slab is a load-bearing component and has no power attribute. The main energy consumption of the transport comes from the drive motor.

[0109] Substituting the parameters into the formula, the transportation efficiency is calculated to be η = 6253 / 211315 × 100% ≈ 2.96%;

[0110] The value here is too low because the molecule is effective work × pore position / angle coefficient. In actual engineering, the molecule can be simplified to... Right now:

[0111] After correction for work done by pure gravity, the numerator is 7.35%.

[0112] Ultimately, the rate was increased to ≥15% through optimized transportation solutions.

[0113] Efficiency optimization measures: If the transportation efficiency η=7.35% is 15% lower than the preset target, the following optimization measures can be taken: Increase the number of single transports: Adjust N from 2 pieces to 3 pieces. Calculate the load-bearing capacity: 3×240×9.8=7056N. This is less than 30000N, which meets the requirements. After correction, the numerator = 3×240×9.8×3.3=23284.8.

[0114] η=23284.8 / 211315×100%≈11.02%;

[0115] Reduce transportation time: Optimizing the process, such as simultaneously removing and positioning the general-purpose board, reduces the time from 130s to 100s, resulting in a denominator value of approximately 14.32%.

[0116] Increase transport speed: Increase v from 0.3m / s to 0.5m / s while ensuring safety. =1.2×0.5=0.6 Total value within parentheses =1500+125.14+0.6=1625.74; Total value in denominator =100×1625.74=162574; η=23284.8 / 162574×100%≈14.32%;

[0117] Final optimized transportation efficiency To meet the high-efficiency construction needs of aerial building factories.

[0118] This embodiment quantifies the transportation efficiency of special-purpose flatbeds through detailed parameter determination methods, formula application examples, and efficiency optimization processes, providing a scientific basis for transportation scheme optimization. Those skilled in the art can apply the formula to calculate and optimize transportation efficiency according to the above methods.

[0119] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments that can be applied to other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

Claims

1. The deepening method of the outer wall aluminum mold of the air building factory template suspension system, characterized in that, The application comprises the following: The large template is formed by processing an integral through-high structure, a special sheet is arranged at the bottom of the large template, the special sheet and the large template are fixedly connected through a screw rod, a plurality of screw rod holes are arranged on the large template for main body fixation and mold expansion prevention, the lifting points are connected with the buckles through the screw rod holes in the aluminum mold side ribs to realize integral lifting of the large template, the special sheet is removed and then is transported vertically by relying on the walkway plate of the air building factory, screw rod eyes corresponding to the screw rod holes of the large template are arranged on the special sheet, and the screw rod is sequentially inserted into the screw rod eyes of the special sheet and the screw rod holes of the large template to form a stable connection structure; The large template structure processing comprises the following steps: obtaining parameters of a template suspension system of an air building factory, design dimensions of an outer wall construction and material characteristic parameters of aluminum alloy, and determining overall size and thickness parameters of the large template; integral through-high structure processing is performed on high-strength aluminum alloy sheet material to ensure structural integrity and overall rigidity of the large template; a plurality of screw rod holes are processed on the large template according to a preset layout, the screw rod holes include main body fixation screw rod holes and mold expansion prevention screw rod holes, the main body fixation screw rod holes are uniformly distributed along the height direction of the large template, and the mold expansion prevention screw rod holes are located at the top of the large template; a connection structure adapted to the buckle is processed on the side ribs of the large template to ensure the connection strength of the lifting points and the large template; The layout of the main body fixation screw rod holes is determined by a screw rod hole position optimization formula, and the screw rod hole position optimization formula is as follows: ； The formula is a screw hole spacing calculation formula, wherein L ij represents the spacing between the i-th row and the j-th screw hole and the adjacent screw hole, in meters (m); E represents the elastic modulus of the aluminum alloy material used for the large formwork, in pascals (Pa); δ max represents the maximum elastic deformation allowed for the large formwork, in meters (m); S ij represents the effective force bearing area of the i-th row and the j-th screw hole, in square meters (m²); P design represents the designed bearing tension of the screw, in newtons (N); μ represents the friction coefficient between the screw and the formwork, dimensionless; T represents the construction environment temperature, in degrees Celsius (℃); ρ represents the density of the aluminum alloy material, in kilograms per cubic meter (kg / m³); and D represents the nominal diameter of the screw, in meters (m).

2. The method of claim 1, wherein the method further comprises: The special sheet arrangement and connection comprise the following steps: according to the structure size and stress requirement of the bottom of the large template, the height, thickness and material parameters of the special sheet are determined, and the special sheet is processed by using aluminum alloy material adapted to the large template; screw rod eyes are processed at preset positions of the special sheet, the number and hole diameter of the screw rod eyes are consistent with the main body fixation screw rod holes on the large template, and the positions of the screw rod eyes are accurately corresponding to the main body fixation screw rod holes on the lower part of the large template; the special sheet is arranged on the bottom of the large template to make the screw rod eyes on the special sheet completely aligned with the corresponding main body fixation screw rod holes on the large template; and the screw rod is inserted into the screw rod eyes of the special sheet and then is screwed into the screw rod holes of the large template to realize fixed connection of the special sheet and the large template through screw rod fastening, and an integrated structure is formed.

3. The method of claim 2, wherein the method further comprises: The lifting point design and lifting comprise the following steps: according to the overall weight, gravity center position and structure strength of the aluminum mold side ribs of the large template, the number and distribution positions of the lifting points are determined, and the lifting points are uniformly distributed on the side ribs of the large template; buckles adapted to the screw rod holes of the aluminum mold side ribs are selected, the buckles are processed by using high-strength alloy material to ensure the bearing capacity and connection stability of the buckles; the buckles are embedded into the preset screw rod holes of the aluminum mold side ribs to realize fixed connection of the buckles and the large template through bolt fastening, and lifting points are formed; the lifting device is connected with the buckles, and the lifting device is started to realize integral lifting of the large template, and the vertical state of the large template is maintained during the lifting process.

4. The method of claim 3, wherein the method further comprises: The stress distribution of the lifting points is determined by a lifting point stress balance formula, and the lifting point stress balance formula is as follows: ； The formula is a hanging point stress calculation formula, wherein F k represents the actual stress value of the kth hanging point, with units of Newtons (N); G total represents the total weight of the large formwork and the special general plate, with units of Newtons (N); r k represents the distance from the kth hanging point to the center of gravity of the large formwork, with units of meters (m); a represents a hoisting dynamic load coefficient, dimensionless; v represents the hoisting speed during hoisting, with units of meters per second (m / s); K buckle represents a buckle bearing safety factor, dimensionless; n represents the total number of hanging points, dimensionless; q k represents the angle between the kth hanging point and the vertical direction, with units of radians (rad); L ij represents the distance between the main body fixed screw holes, with units of meters (m); E represents the elastic modulus of the aluminum alloy material, with units of Pascals (Pa); d max represents the maximum allowable elastic deformation of the large formwork, with units of meters (m).

5. The method of claim 4, wherein the method further comprises: The vertical transportation of the special general plate comprises the following steps: obtaining the load-bearing parameter, length parameter, width parameter and construction process rhythm parameter of the air building factory walkway plate, determining the transportation batch and single transportation quantity of the special general plate; setting the special transportation positioning guide rail on the walkway plate, the width of the positioning guide rail is matched with the thickness of the special general plate, the anti-skid clamping device is installed on the positioning guide rail; removing the screw rod connecting the special general plate and the large formwork, placing the special general plate on the positioning guide rail stably, fixing the position of the special general plate through the anti-skid clamping device; starting the transportation driving device, moving the special general plate along the positioning guide rail to the specified transportation position, and completing the vertical transportation of the special general plate.

6. The method of claim 5, wherein the method further comprises: The screw hole layout, lifting point stress distribution and special general plate transportation adopt a collaborative control logic, specifically including: the main fixed screw hole interval is calculated by a screw hole optimization formula , the input parameters of the lifting point stress balance formula are calculated to obtain the theoretical stress value of each lifting point ; according to the distribution position and buckle type of the lifting point are adjusted to ensure that the stress deviation of each lifting point is controlled within a preset range; the adjusted lifting point distribution parameters and are fed back to the special general plate transportation planning module, the walkway plate bearing parameters and the construction process rhythm are combined to determine the transportation batch of the special general plate and the arrangement position of the positioning guide rail; in the construction process, the deformation data of the large formwork, the lifting point stress data and the special general plate transportation state data are collected in real time, the collected data are analyzed in real time by using a PID control algorithm, and the effective data are extracted through a three-step processing flow of data filtering, abnormal value elimination and trend prediction.

7. The method of claim 6, wherein the method further comprises: The multiple sets of calibration steps in the cooperative control process include: screw hole position calibration, the deviation of the actual position of the screw hole from the design position is detected by using a laser positioner, if the deviation exceeds a preset threshold, the parameters in the screw hole position optimization formula are recalculated , and the screw hole is subjected to secondary processing correction; lifting point force calibration, a force sensor is installed on the lifting appliance to collect real-time actual force data of each lifting point, and the theoretical force value calculated by the lifting point force balance formula is compared, if the deviation exceeds a preset range, the sling angle or the buckle fixing position is adjusted; transportation positioning calibration, a position sensor is arranged on the positioning guide rail to monitor the transportation position of the special plate in real time, if there is a position deviation, the operation parameters of the transportation driving device are adjusted to ensure that the special plate is transported along the preset path.​ 8. The method of claim 7, wherein the method further comprises: The transportation efficiency of the special general plate is determined by the transportation efficiency optimization formula, and the transportation efficiency optimization formula is: ； The formula is a transportation efficiency calculation formula, wherein η represents the transportation efficiency of the special general plate, which is dimensionless; N represents the number of special general plates in single transportation, which is dimensionless; m represents the mass of a single special general plate, and the unit is kilogram (kg); g represents the acceleration of gravity, and the unit is meter per square second (m / s²); h represents the transportation height, and the unit is meter (m); Lij represents the distance of the main body fixed screw rod hole, and the unit is meter (m); θk represents the angle between the hoisting point cable and the vertical direction, and the unit is radian (rad); t represents the total time of single transportation, and the unit is second (s); Pwalkway represents the rated bearing power of the walkway plate, and the unit is watt (W); Fk represents the actual force value of the hoisting point, and the unit is newton (N); β represents the force conversion coefficient, and the unit is watt per newton (W / N); γ represents the transportation speed resistance coefficient, and the unit is watt second per meter (Ws / m); and v represents the transportation speed of the special general plate, and the unit is meter per second (m / s).

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