Inner formwork transporting and supporting system for prefabricated box girder and using method

Abstract

The invention discloses an inner formwork transporting and supporting system for a prefabricated box girder and a using method. The system comprises a support, a horizontal driving assembly, a bearing assembly and a controller. The horizontal driving assembly is arranged on the support, the bearing assembly comprises a supporting base, a driving piece, a first adjustable supporting piece, a second adjustable supporting piece and a third adjustable supporting piece, and the supporting base is installed on the support in a sliding mode; the driving piece is fixedly mounted on the supporting seat and is in power connection with the horizontal driving assembly; a plurality of auxiliary rolling assemblies are arranged on the two sides of the supporting base, each auxiliary rolling assembly comprises a linear driving component, a swing piece and a walking wheel, and the controller is used for controlling the horizontal driving assembly, the linear driving components, the first adjustable supporting piece, the second adjustable supporting piece and the third adjustable supporting piece to act; the method comprises the steps of operation preparation, inner mold supporting and mold removal operation. The system is high in disassembly and assembly efficiency, manual operation in a narrow space is avoided, and the construction efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of precast box girder manufacturing technology, specifically to an internal formwork transportation and support system for precast box girders and its usage method. Background Technology

[0002] Traditional box girder construction methods primarily employ cast-in-place techniques, involving a series of on-site operations such as formwork erection, rebar tying, and concrete pouring. This method has several drawbacks, including a long construction period, significant susceptibility to weather and seasonal factors, high manual labor requirements, and low construction efficiency. Furthermore, on-site concrete pouring is prone to issues such as inadequate compaction and poor appearance, which negatively impact the overall quality of the box girder. In addition, cast-in-place construction generates substantial construction waste, causing significant environmental pollution, and prolonged road closures in busy urban areas severely disrupt traffic flow.

[0003] To address the problems associated with traditional cast-in-place box girder construction, precast box girder technology emerged. Precast box girders are manufactured uniformly in a prefabrication plant according to design specifications and then transported to the construction site for hoisting. This technology offers significant advantages. In terms of construction efficiency, the segmental prefabrication of box girders significantly reduces weight, simplifies transportation and hoisting, and enables precast assembly, greatly improving construction speed.

[0004] However, when supporting the formwork inside the box culvert of the precast box girder, the limited space inside the box culvert makes it impossible to use large lifting and transportation equipment. Only multiple operators can work together, which makes the construction difficult and inefficient. Summary of the Invention

[0005] The purpose of this invention is to provide a transportation and support system and method for precast box girder internal formwork, which solves the problem of difficulty in supporting and disassembling internal formwork caused by space limitations in box culverts in the prior art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A precast box girder internal formwork transportation and support system includes a support frame, a horizontal drive assembly, a load-bearing assembly, and a controller; The support is set on the ground, located on one side of the precast box girder; The horizontal drive component is mounted on the support and is used to drive the load-bearing component to move horizontally. The load-bearing assembly includes a support base, a drive component, a first adjustable support component, a second adjustable support component, and a third adjustable support component. The support base is slidably mounted on a bracket. The drive component is fixedly mounted on the support base and is dynamically connected to a horizontal drive assembly. One end of each of the first adjustable support components is fixedly mounted on the support base, and the other end of each of the first adjustable support components is connected to the bottom of the upper inner mold. One end of each of the second adjustable support components is hinged to the bottom of the upper inner mold, and the other end of each of the second adjustable support components is hinged to the inner side of the side inner mold. One end of each of the third adjustable support components is hinged to the support base, and the other end of each of the third adjustable support components is hinged to the inner side of the side inner mold. Multiple auxiliary rolling components are provided on both sides of the support base. Each auxiliary rolling component includes a linear drive component, a swing component, and a traveling wheel. One end of the linear drive component is connected to the support base, and the other end of the linear drive component is movably connected to one end of the swing component. The swing component is hinged to the support base, and the traveling wheel is rotatably disposed at the other end of the swing component. The controller is used to control the horizontal drive assembly, the linear drive component, the first adjustable support, the second adjustable support, and the third adjustable support to perform their actions.

[0007] Preferably, the support is a cubic frame assembled from several steel sections; multiple adjustable legs are provided at the bottom of the support.

[0008] Preferably, a plurality of rollers are provided on both sides of the top of the bracket, and the support seat slides on the rollers.

[0009] Preferably, the horizontal drive assembly includes a drive motor, a drive shaft, and a drive sprocket. The drive motor is fixedly mounted on the bracket, the drive shaft is rotatably mounted on the bracket, the drive shaft is poweredly connected to the output end of the drive motor, and the drive sprocket is fixedly mounted on the drive shaft.

[0010] Preferably, when the linear drive member extends, it drives the swing member to rotate around the hinge axis, so that the bottom of the walking wheel is lower than the bottom of the support base; when the linear drive member retracts, it drives the swing member to rotate around the hinge axis, so that the bottom of the walking wheel is higher than the bottom of the support base.

[0011] Preferably, the driving component is a drive chain fixedly mounted on the support base, and the drive chain is meshed with the drive sprocket.

[0012] Preferably, an auxiliary support is detachably installed at one end of the support base, and the auxiliary support is slidably installed on the roller; an auxiliary chain is fixedly installed on the auxiliary support, and the auxiliary chain is meshed with the drive sprocket.

[0013] A method for using an internal formwork transportation and support system for precast box girders, the method comprising the following steps: Step 1, Work Preparation: Assemble the upper inner mold and two side inner molds onto the load-bearing assembly; retract the first, second, and third adjustable supports so that the upper inner mold and two side inner molds are located inside the installation position; control the linear drive component to extend so that the bottom of the traveling wheels is lower than the bottom of the support base; activate the horizontal drive component to insert the load-bearing assembly with the upper inner mold and side inner molds into the box culvert; Step 2, Inner mold support: After the load-bearing components containing the upper inner mold and side inner molds are adjusted into place, control the linear drive component to retract so that the bottom of the traveling wheel is higher than the bottom of the support seat, and the support seat is placed on the ground; extend the first adjustable support component, the second adjustable support component, and the third adjustable support component so that the upper inner mold and the two side inner molds are in the installation position. Step 3: Demolding. After the precast box girder is poured and reaches the design strength, retract the first, second, and third adjustable supports to position the upper inner mold and the two side inner molds inside the installation position, thus removing the upper inner mold and the two side inner molds. Control the retraction of the linear drive component so that the bottom of the traveling wheel is lower than the bottom of the support base. Activate the horizontal drive component to discharge the load-bearing component with the upper inner mold and the side inner molds from the box culvert. Clean and spray the surfaces of the upper inner mold and the two side inner molds with release agent, ready for the next operation.

[0014] Compared with the prior art, the system of this invention has the following advantages: 1. Stable structure and strong adaptability: The support frame is made of steel sections spliced ​​into a cubic frame, combined with multiple adjustable legs at the bottom that can be adjusted by threads. This not only allows for flexible adjustment of the top height of the support frame to meet different operational needs, but also effectively adapts to uneven ground, ensuring the stability of the entire system after installation and providing a solid foundation for the subsequent transportation and support of the inner formwork.

[0015] 2. Achieving efficient horizontal movement of the inner formwork: The horizontal drive component, through the cooperation of a drive motor, drive shaft, drive sprocket, and drive chain on the load-bearing component, can stably drive the load-bearing component to slide horizontally on the rollers of the support. This chain drive method ensures reliable power transmission, enabling smooth and precise movement of the inner formwork, facilitating its rapid insertion or removal from the box culvert and improving operational efficiency.

[0016] 3. Flexible and precise adjustment of the inner formwork position: The first, second, and third adjustable supports in the load-bearing components all use hydraulic cylinders, whose extension and retraction are controlled by a controller, allowing for precise adjustment of the height of the upper inner formwork and the angle and lateral position of the side inner formwork. This enables the inner formwork to quickly and accurately reach the installation position, ensuring the casting quality of the precast box girder, and also facilitating formwork removal operations.

[0017] 4. Reduced frictional resistance and damage risk during movement: The auxiliary rolling components on both sides of the support base, driven by linear drive components (hydraulic cylinders), can flexibly control the raising and lowering of the traveling wheels. When the load-bearing components are inserted into or removed from the box culvert, the traveling wheels roll in contact with the ground, significantly reducing frictional resistance and making movement smoother; while during operation, the traveling wheels are retracted, without affecting the stability of the support. In addition, by retracting the adjustable support components, the inner formwork is positioned inside the installation position during movement, avoiding friction with the inner wall of the box culvert and reducing damage to the surface of the inner formwork.

[0018] 5. Auxiliary support design enhances system practicality: The auxiliary support is detachably installed at one end of the support base, which can extend the length of the support base when needed to ensure that the inner template is installed in place; when dismantling the formwork and expelling the load-bearing components, the auxiliary support is installed and cooperates with the drive sprocket through the auxiliary chain to ensure effective power transmission, so that the load-bearing components can be moved out smoothly, enhancing the applicability of the system in different operation stages.

[0019] The entire system uses a PLC programmable controller to centrally control the horizontal drive components, adjustable supports, and auxiliary rolling components, automating the transportation, support, and dismantling of the inner formwork. This not only reduces manual intervention and labor intensity but also improves the accuracy and consistency of operations, helping to ensure construction safety and project progress. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the overall structure of the present invention from another perspective; Figure 3 This is a schematic diagram of the auxiliary scrolling component structure of the present invention; In the diagram: 1. Bracket; 2. Horizontal drive assembly; 3. Bearing assembly; 4. Controller; 5. Auxiliary rolling assembly; 6. Adjustable support leg; 7. Roller; 8. Auxiliary support; 9. Auxiliary chain; 10. Upper inner mold; 11. Side inner mold; 20. Drive motor; 21. Drive shaft; 22. Drive sprocket; 30. Support base; 31. Drive component; 32. First adjustable support component; 33. Second adjustable support component; 34. Third adjustable support component; 50. Linear drive component; 51. Swing component; 52. Traveling wheel. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings: like Figures 1 to 3 The present invention relates to a precast box girder internal formwork transportation and support system, comprising a support 1, a horizontal drive assembly 2, a load-bearing assembly 3, and a controller 4; the support 1 is set on the ground and located on one side of the precast box girder to support the load-bearing assembly 3.

[0022] The bracket 1 is a cubic frame assembled from several steel sections. Multiple adjustable legs 6 are threaded onto the bottom of the bracket 1. The adjustable legs 6 can adjust the top height of the bracket 1 and adapt to uneven ground, ensuring installation stability.

[0023] The horizontal drive assembly 2 is mounted on the bracket 1 and is used to drive the load-bearing assembly 3 to move horizontally. The horizontal drive assembly 2 includes a drive motor 20, a drive shaft 21, and a drive sprocket 22. The drive motor 20 is fixedly mounted on the bracket 1 via a motor bracket, and the drive shaft 21 is rotatably mounted on the bracket 1 via a bearing seat. The output end of the drive shaft 21 and the drive motor 20 are poweredly connected via a chain drive component, and the drive sprocket 22 is fixedly mounted on the drive shaft 21. When the drive motor 20 is energized and rotates, it drives the drive shaft 21 to rotate via the chain drive component, thereby causing the drive sprocket 22 to rotate.

[0024] The supporting component 3 includes a support base 30, a driving member 31, a first adjustable support member 32, a second adjustable support member 33, and a third adjustable support member 34. The support base 30 is slidably mounted on the bracket 1. In this embodiment, a plurality of rollers 7 are rotatably arranged on both sides of the top of the bracket 1, and the support base 30 slides on the rollers 7. The support base 30 has a groove adapted to the rollers 7, and the rollers 7 are located in the groove.

[0025] The drive component 31 is fixedly mounted on the support base 30 and is poweredly connected to the horizontal drive assembly 2. Specifically, the drive component 31 is a drive chain fixedly mounted on the support base 30, and the drive chain is meshed with the drive sprocket 22. When the drive sprocket 22 rotates, it drives the support base 30 to move horizontally through the meshing transmission with the drive chain.

[0026] One end of each of the multiple first adjustable support members 32 is fixedly installed on the support base 30, and the other end of each of the multiple first adjustable support members 32 is connected to the bottom of the upper inner mold 10; the first adjustable support members 32 are hydraulic cylinders, and the height of the upper inner mold 10 is controlled by the extension and retraction of the multiple first adjustable support members 32.

[0027] One end of a plurality of second adjustable support members 33 is hinged to the bottom of the upper inner mold 10, and the other end of the plurality of second adjustable support members 33 is hinged to the inner side of the side inner mold 11; one end of a plurality of third adjustable support members 341 is hinged to the support base 30, and the other end of the plurality of third adjustable support members 34 is hinged to the inner side of the side inner mold 11. The second adjustable support members 33 and the third adjustable support members 34 are hydraulic cylinders, and the angle and lateral position of the side inner mold 11 are controlled by controlling the extension and retraction of the second adjustable support members 33 and the third adjustable support members 34.

[0028] Multiple auxiliary rolling components 5 are provided on both sides of the support base 30. Each auxiliary rolling component 5 includes a linear drive component 50, a swing component 51, and a traveling wheel 52. One end of the linear drive component 50 is connected to the support base 30, and the other end of the linear drive component 50 is movably connected to one end of the swing component 51. The swing component 51 is hinged to the support base 30, and the traveling wheel 52 is rotatably disposed at the other end of the swing component 51. Specifically, the linear drive component 50 is a hydraulic cylinder.

[0029] In this embodiment, one end of the linear drive component 50 is fixedly connected to the support base 30, and the other end of the linear drive component 50 is movably connected to one end of the swing component 51 via a pin and a sliding groove. When the linear drive component 50 extends, it drives the swing component 51 to rotate around the hinge axis, so that the bottom of the traveling wheel 52 is lower than the bottom of the support base 30; when the linear drive component 50 retracts, it drives the swing component 51 to rotate around the hinge axis, so that the bottom of the traveling wheel 52 is higher than the bottom of the support base 30.

[0030] An auxiliary support 8 is detachably installed at one end of the support base 30 via fasteners. The auxiliary support 8 is slidably mounted on the roller 7. The function of the auxiliary support 8 is to extend the support base 30. After the upper inner mold 10 and the side inner mold 11 are installed in place, the auxiliary support 8 is removed. An auxiliary chain 9 is fixedly installed on the auxiliary support 8, and the auxiliary chain 9 is meshed with the drive sprocket 22. When the demolding operation is completed and the load-bearing component 3 needs to be discharged, the auxiliary support 8 is reinstalled, so that the auxiliary chain 9 is poweredly connected to the drive sprocket 22.

[0031] Controller 4 is used to control the horizontal drive assembly 2, the linear drive component 50, the first adjustable support 32, the second adjustable support 33, and the third adjustable support 34 to perform their actions. Controller 4 is a PLC programmable controller.

[0032] like Figures 1 to 3 The method of using an internal formwork transportation and support system for precast box girders, as shown, includes the following steps: Step 1, work preparation: Assemble the upper inner mold 10 and the two side inner molds 11 onto the bearing assembly 3. Specifically, the bottom of the upper inner mold 10 is connected to the ends of the first adjustable support 32 and the second adjustable support 33, and the inner side of the side inner molds 11 is connected to the ends of the second adjustable support 33 and the third adjustable support 34. By retracting the first adjustable support 32, the second adjustable support 33, and the third adjustable support 34 through the controller 4, the upper inner mold 10 and the two side inner molds 11 are located inside the installation position, with gaps during overall horizontal movement, to avoid increasing movement resistance due to friction, and also to avoid damage to the surfaces of the upper inner mold 10 and the two side inner molds 11.

[0033] The controller 4 controls the linear drive component 50 to extend, so that the bottom of the walking wheel 52 is lower than the bottom of the support base 30; the horizontal drive component 2 is activated so that the load-bearing component 3, which is equipped with the upper inner mold 10 and the side inner mold 11, is inserted into the box culvert. During the insertion process, the walking wheel 52 rolls on the contact surface to reduce frictional resistance.

[0034] Step two, inner mold support: After the load-bearing assembly 3, which contains the upper inner mold 10 and the side inner molds 11, is adjusted to the installation position, the linear drive component 50 is retracted by the controller 4, so that the bottom of the traveling wheel 52 is higher than the bottom of the support base 30, thereby allowing the support base 30 to land. The controller 4 extends the first adjustable support component 32, the second adjustable support component 33, and the third adjustable support component 34, so that the upper inner mold 10 and the two side inner molds 11 are in the installation position, completing the installation of the inner mold.

[0035] Step 3, demolding operation: After the precast box girder is poured and reaches the design strength, the controller 4 retracts the first adjustable support 32, the second adjustable support 33 and the third adjustable support 34, so that the upper inner mold 10 and the two side inner molds 11 are located inside the installation position, thereby removing the upper inner mold 10 and the two side inner molds 11.

[0036] The controller 4 controls the linear drive component 50 to retract, so that the bottom of the walking wheel 52 is lower than the bottom of the support base 30; the controller 4 activates the horizontal drive component 2, so that the load-bearing component 3, which is equipped with the upper inner mold 10 and the side inner mold 11, is discharged from the box culvert; the surface of the upper inner mold 10 and the two side inner molds 11 are cleaned and sprayed with release agent, waiting for the next operation.

[0037] The above embodiments are merely illustrative of the concept and implementation of the present invention and are not intended to limit it. Under the concept of the present invention, technical solutions without substantial changes are still within the scope of protection.

Claims

1. A transportation and support system for internal formwork of precast box girders, characterized in that: It includes a support (1), a horizontal drive assembly (2), a load-bearing assembly (3), and a controller (4); The support (1) is set on the ground and located on one side of the precast box girder; The horizontal drive component (2) is mounted on the bracket (1) and is used to drive the load-bearing component (3) to move horizontally; The bearing assembly (3) includes a support base (30), a drive member (31), a first adjustable support member (32), a second adjustable support member (33), and a third adjustable support member (34). The support base (30) is slidably mounted on the bracket (1). The drive member (31) is fixedly mounted on the support base (30) and is poweredly connected to the horizontal drive assembly (2). One end of each of the first adjustable support members (32) is fixedly mounted on the support base (30), and the other end of each of the first adjustable support members (32) is connected to the bottom of the upper inner mold (10). One end of each of the second adjustable support members (33) is hinged to the bottom of the upper inner mold (10), and the other end of each of the second adjustable support members (33) is hinged to the inner side of the side inner mold (11). One end of each of the third adjustable support members (34) is hinged to the support base (30), and the other end of each of the third adjustable support members (34) is hinged to the inner side of the side inner mold (11). Multiple auxiliary rolling components (5) are provided on both sides of the support base (30). The auxiliary rolling components (5) include a linear drive component (50), a swing component (51) and a traveling wheel (52). One end of the linear drive component (50) is connected to the support base (30), and the other end of the linear drive component (50) is movably connected to one end of the swing component (51). The swing component (51) is hinged to the support base (30), and the traveling wheel (52) is rotatably disposed at the other end of the swing component (51). The controller (4) is used to control the horizontal drive assembly (2), the linear drive component (50), the first adjustable support (32), the second adjustable support (33) and the third adjustable support (34) to perform actions.

2. The precast box girder internal formwork transportation and support system according to claim 1, characterized in that: The support (1) is a cubic frame spliced ​​from several steel sections; multiple adjustable legs (6) are provided at the bottom of the support (1).

3. The precast box girder internal formwork transportation and support system according to claim 1 or 2, characterized in that: Several rollers (7) are provided on both sides of the top of the bracket (1), and the support seat (30) slides on the rollers (7).

4. The precast box girder internal formwork transportation and support system according to claim 4, characterized in that: The horizontal drive assembly (2) includes a drive motor (20), a drive shaft (21) and a drive sprocket (22). The drive motor (20) is fixedly mounted on the bracket (1). The drive shaft (21) is rotatably mounted on the bracket (1). The drive shaft (21) is poweredly connected to the output end of the drive motor (20). The drive sprocket (22) is fixedly mounted on the drive shaft (21).

5. The precast box girder internal formwork transportation and support system according to claim 1, characterized in that: When the linear drive member (50) extends, it drives the swing member (51) to rotate around the hinge axis, so that the bottom of the walking wheel (52) is lower than the bottom of the support seat (30); when the linear drive member (50) retracts, it drives the swing member (51) to rotate around the hinge axis, so that the bottom of the walking wheel (52) is higher than the bottom of the support seat (30).

6. The precast box girder internal formwork transportation and support system according to claim 4, characterized in that: The driving component (31) is a driving chain fixedly installed on the support base (30), and the driving chain is meshed with the driving sprocket (22).

7. The precast box girder internal formwork transportation and support system according to claim 4 or 6, characterized in that: An auxiliary support (8) is detachably installed at one end of the support base (30), and the auxiliary support (8) is slidably installed on the roller (7); an auxiliary chain (9) is fixedly installed on the auxiliary support (8), and the auxiliary chain (9) is meshed with the drive sprocket (22).

8. A method of using the precast box girder internal formwork transportation and support system according to any one of claims 1 to 7, characterized in that: The method of use includes the following steps: Step 1, work preparation: Assemble the upper inner mold (10) and two side inner molds (11) on the load-bearing component (3), retract the first adjustable support (32), the second adjustable support (33) and the third adjustable support (34) so ​​that the upper inner mold (10) and the two side inner molds (11) are located inside the installation position; control the linear drive component (50) to extend so that the bottom of the walking wheel (52) is lower than the bottom of the support seat (30); start the horizontal drive component (2) so that the load-bearing component (3) with the upper inner mold (10) and the side inner molds (11) installed is inserted into the box culvert; Step 2, inner mold support: After the load-bearing component (3) containing the upper inner mold (10) and the side inner mold (11) is adjusted into place, the linear drive component (50) is controlled to retract, so that the bottom of the walking wheel (52) is higher than the bottom of the support seat (30), and the support seat (30) is placed on the ground; the first adjustable support (32), the second adjustable support (33) and the third adjustable support (34) are extended, so that the upper inner mold (10) and the two side inner molds (11) are in the installation position; Step 3, demolding operation: After the precast box girder is poured and reaches the design strength, shrink the first adjustable support (32), the second adjustable support (33) and the third adjustable support (34) so ​​that the upper inner mold (10) and the two side inner molds (11) are located inside the installation position, and the upper inner mold (10) and the two side inner molds (11) are removed; control the linear drive component (50) to shrink so that the bottom of the walking wheel (52) is lower than the bottom of the support seat (30); start the horizontal drive component (2) so that the load-bearing component (3) with the upper inner mold (10) and the side inner molds (11) installed is discharged from the box culvert; clean the surface of the upper inner mold (10) and the two side inner molds (11) and spray release agent, and wait for the next operation.

Images