Tenon integrated forming device, subway station bottom plate and construction technology

Abstract

The invention provides a tenon integrated forming device, a subway station bottom plate and a construction technology, and the tenon integrated forming device comprises an equipment body which is movably connected to a bottom plate main body and moves back and forth relative to the bottom plate main body; the positioning synchronous lifting device is connected to the end part of the equipment body and moves up and down relative to the bottom plate main body; the mold pouring device is connected to the lower part of the positioning synchronous lifting device; the mold pouring device comprises a mold assembly and a pressing plate, the positioning synchronous lifting device is connected with the pressing plate, and the pressing plate is connected with the mold assembly; a top surface elevation monitoring device is arranged on the equipment body and is used for monitoring the height of the mold assembly; the controller is used for adjusting the positioning synchronous lifting device according to data of the top face elevation monitoring device, the positioning synchronous lifting device drives the pressing plate and the mold assembly to move synchronously, and the device can adapt to large-depth supporting complex underground space operation, is flexible and convenient to transfer, and is high in construction precision, reliable in structure and easy to operate.

Description

Technical Field

[0001] This invention belongs to the field of prefabricated subway station construction technology, and specifically relates to an integrated tenon molding device, a subway station base plate, and a construction process. Background Technology

[0002] New-type industrialized construction is one of the trends in contemporary building technology development. Many countries regard prefabrication as an important indicator of technological development. With the development of technology, prefabricated components are gradually being applied to subway construction. Prefabricated technology, due to its advantages such as fast construction speed, small footprint, labor saving, and low carbon emissions, has become the future development trend of subway construction. In the construction of prefabricated subway stations, the process involves casting the base slab in place, while prefabricating the side walls, middle slabs, and top slabs. The cast-in-place base slab is then assembled with the prefabricated side walls and top slabs, forming a process that combines the cast-in-place base slab with the assembled superstructure of the subway station.

[0003] Currently, in the on-site construction process combining cast-in-place foundation slab with superstructure assembly, the position of the tenon structure at the end nodes of the cast-in-place foundation slab is generally determined by first positioning it with steel supports before rebar tying, then installing bolts on the upper end of the steel supports, and finally positioning the top formwork by fixing the bolts. After the bolts are inserted into the formwork, the top nut of the formwork is fixed by measurement and manual adjustment. The formwork is then laid continuously, and the foundation slab is poured as a whole. This process not only requires highly skilled on-site operators, but the bolt positioning is also prone to change during rebar tying and welding, and manual adjustments are also subject to errors. Furthermore, subsequent construction processes such as side formwork laying, pouring, and vibration can all affect the position of the formwork. Therefore, the existing operating process may result in improper control of the top surface elevation of the tenon structure at both ends of the cast-in-place foundation slab, or formwork displacement, causing unevenness and spacing on both sides, failure to meet flatness requirements, or changes in the position of the tenon, leading to problems in the accuracy control of the connection nodes. In addition, the initial positioning requires a large number of steel supports, resulting in some waste.

[0004] The invention patent with publication number CN117627678A describes an intelligent formwork system for improving the construction accuracy of cast-in-place components. Although the construction accuracy of the invert arch end can be achieved by hoisting the formwork system, it greatly slows down the construction progress by pouring the bottom plate ring by ring separately. After the construction and curing of one pouring position is completed, the formwork is removed and then adjusted to the next pouring position before moving to the next construction section. Moreover, the application scope of this technical solution is limited. It is difficult to apply to open-cut underground space construction operations because the foundation pit is deep, the support structure is complex, the hoisting construction is difficult, the interference is strong, and multiple types of workers are required. The safety and operability of hoisting make it difficult to implement.

[0005] In addition, the seismic performance and waterproof performance of the connection nodes at the ends of the cast-in-place base slab have always been key issues in prefabricated subway station structures. Meanwhile, ordinary concrete poured later may not meet the structural stress requirements.

[0006] Therefore, there is an urgent need for a tenon-and-mortise integrated molding device, subway station base plate and construction process that is adaptable to complex underground space operations with deep support, flexible and convenient to move, and has high construction accuracy, reliable structure and easy operation, so as to make up for the shortcomings of existing technologies. Summary of the Invention

[0007] To address the aforementioned shortcomings of existing technologies, this invention proposes an integrated tenon-and-groove molding device, a subway station base slab, and a construction process. This device is adaptable to complex underground space operations requiring deep support, offers flexible and convenient relocation, high construction precision, reliable structure, and ease of operation. The solution is as follows: On one hand, this invention proposes an integrated tenon molding device for casting tenon structures on the main body of a base plate, comprising: The main body of the equipment is movably connected to the base plate and can move back and forth relative to the base plate. A positioning and synchronous lifting device is connected to the end of the equipment body and moves up and down relative to the base plate body; A casting device is connected to the lower part of a positioning and synchronous lifting device; the casting device includes a mold assembly and a pressure plate, the positioning and synchronous lifting device is connected to the pressure plate, and the pressure plate is connected to the mold assembly; a top surface elevation monitoring device is provided on the equipment body to monitor the height of the mold assembly; The controller is used to adjust the positioning and synchronous lifting device according to the data from the top surface elevation monitoring device. The positioning and synchronous lifting device drives the pressure plate and mold assembly to move synchronously.

[0008] Furthermore, the equipment body includes multiple steel frame modules, Γ-shaped modules located at both ends and symmetrically arranged, and a driving and braking device. A top surface elevation monitoring device is installed on the outer section of the Γ-shaped module, and a casting device is connected to the lower part of the Γ-shaped module.

[0009] Furthermore, the driving and braking device includes a driving device and a driven device. The driving device includes a power device fixed to the equipment body and a gear and rack mechanism connected to the power device. The driven device is located at the bottom of the equipment body and includes a pulley and slide rail mechanism. The power unit drives the gears of the gear and rack mechanism to move relative to the rack, which in turn drives the pulleys of the pulley and slide rail mechanism to move relative to the slide rail, thereby realizing the movement of the equipment body relative to the base plate.

[0010] Furthermore, the mold assembly includes a cover mold, a first side mold, a second side mold, and a front / rear mold. The cover mold is fixedly connected to the front / rear mold, movably connected to the first side mold, and fixedly connected to the second side mold. The first side mold is movably connected to the front / rear mold. The upper surface of the cover mold has multiple sets of protrusions, and the upper end of each protrusion has a casting window. The first side formwork is also provided with a first adjustment device and a second adjustment device with telescopic function. The first adjustment device abuts against the top surface of the poured fertilizer tank and is used to drive the first side formwork to move vertically. The second adjustment device abuts against the side wall of the foundation pit and is used to provide lateral support force for the first side formwork. The second side mold includes a top plate and an arc-shaped mold. The top plate is fixedly connected to the cover mold and is located on the same horizontal plane. The arc of the arc-shaped mold is the same as the arc of the main body of the bottom plate. A third adjustment device with telescopic function is provided between the top plate and the arc-shaped mold to provide vertical support force.

[0011] Furthermore, at least one positioning pin sleeve is fixed along the length direction on the inner side of the pouring window.

[0012] Furthermore, the mold assembly also includes a sliding connection assembly and an insertion assembly. The first side mold and the cover mold are slidably connected through the sliding connection assembly, and the first side mold and the front / rear mold are connected by the insertion assembly. The sliding groove of the sliding connection component and the slot of the plug-in component are set on the first side mold, the slider of the sliding connection component is set on the cover mold, and the plug block of the plug-in component is set on the front / rear mold.

[0013] Furthermore, the front / rear mold includes at least one splicing template, and adjacent splicing templates are detachably connected; the end faces of the rear / front mold located at the first and last rings of the base plate casting need to be fixed with a fourth adjustment device with telescopic function to provide lateral support.

[0014] Furthermore, the positioning and synchronous lifting device includes a linkage lifting machine; the linkage lifting machine is set as a linkage screw lifting machine, with at least 2n+2 screws, where n is the number of rings assembled in one assembly of the prefabricated subway station.

[0015] On the other hand, the present invention also proposes a subway station base plate, including a base plate body, and a tenon structure and an arc structure cast by the aforementioned tenon integrated molding device. During construction, after the base plate body is cast, the tenon structure and the arc structure are cast by the tenon integrated molding device.

[0016] Furthermore, this invention also proposes a construction process for subway station foundation slabs, applicable to the aforementioned subway station foundation slabs, comprising the following steps: S1. Reinforcing bar binding, pouring the main body of the base slab, with reserved post-cast portions and reinforcing bars at both ends; S2. After the main body of the base plate meets the strength requirements, the base plate track is laid according to the construction axis. The base plate track is used to connect the equipment body and assemble the equipment body. S3. The casting device is fixed to the lower part of both ends of the equipment body by a positioning and synchronous lifting device; S4. The height of the mold assembly is monitored in real time by the top surface elevation monitoring device, and the controller adjusts the vertical movement of the positioning synchronization device to drive the mold assembly to move synchronously to adjust the elevation to the design position; S5. Adjust the vertical height of the side mold of the mold assembly. After fixing the mold assembly, confirm the elevation of the mold assembly again through the top surface elevation monitoring device to ensure the elevation is accurate. S6. The secondary pump truck pours ultra-high performance concrete into the pouring window above the mold assembly; S7. The controller controls the positioning synchronous lifting device to retract, the positioning synchronous lifting device separates from the pressure plate of the casting device, and the casting device remains in place to wait for the subsequent casting part to cure and form; the controller controls the operation of the travel and braking device of the equipment body, and the travel and braking device drives the equipment body to move to the preset displacement value and then stops. S8. Repeat steps S3 to S5 to continue pouring the next set; S9. After the post-pouring section has been cured and formed, the equipment body returns under the control of the controller, the constraints are removed, the mold assembly is demolded, and the demolded casting device continues to be used for the next set of castings.

[0017] Compared with the prior art, the advantages of the present invention are as follows: This invention utilizes a symmetrical, integrated tenon forming device to control the precise forming of tenons at the end nodes of prefabricated subway station base slabs. This ensures consistency in elevation, tenon spacing, position, and flatness of the post-cast sections on both sides, achieving a precise connection between the cast-in-place base slab and precast components during installation. It reduces misalignment and flatness issues, preventing problems with elevation and spacing on both sides of the main structure and ensuring the stability of the cast-in-place base slab and the entire prefabricated structure. Furthermore, the device boasts a robust structure, adjustable span, and easy assembly and disassembly, significantly reducing worker workload, ensuring safety, reliability, and high construction efficiency. After curing, the casting mold can be reused in subsequent casting stages, reducing mold usage. The molds are reusable throughout the casting process, reducing mold manufacturing costs. This invention also enables precise positioning of the base slab during casting, eliminating the need for steel section positioning before reinforcing bar tying during base slab construction, thus reducing steel consumption. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the tenon-and-groove integrated forming device according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of the base plate body according to an embodiment of the present invention; Figure 3 This is a structural schematic diagram of an embodiment of the present invention; Figure 4 This is a schematic diagram of the casting device of the present invention located on the base plate body. Figure 1 ; Figure 5 This is a schematic diagram of the mold component structure according to an embodiment of the present invention. Figure 1 ; Figure 6 This is a schematic diagram of the connection between the first and second splicing templates in this invention. Figure 7 This is a schematic diagram of the first side mold structure according to an embodiment of the present invention; Figure 8 This is an enlarged schematic diagram of a partial structure of the first side mold in an embodiment of the present invention; Figure 9 This is a schematic diagram of the combined structure of the cover mold and the second side mold in an embodiment of the present invention. Figure 2 ; Figure 10 This is an enlarged schematic diagram of a partial structure of the cover mold according to an embodiment of the present invention; Figure 11 This is a schematic diagram of the casting device of the present invention located on the base plate body. Figure 2 ; Figure 12 This is a schematic diagram of the casting device of the present invention located on the base plate body. Figure 3 ; Figure 13 This is a schematic diagram of the state after the casting device is fixed according to an embodiment of the present invention; Figure 14 This is a construction flowchart of the subway station base plate according to an embodiment of the present invention.

[0019] In the above figures: 1. Trolley; 11. Steel frame module; 12. U-shaped module; 121. Top surface elevation monitoring device; 122. Cantilever frame; 123. Hollowed-out structure in the middle; 13. Traveling and braking device; 131. Power unit; 132. Gear and rack mechanism; 1321. Rack; 133. Pulley and slide rail mechanism; 1331. Track; 2. Casting device; 21. Mold assembly; 211. Cover mold; 2111. Protrusion; 2112. Locating pin sleeve; 2113. Slider of sliding connection assembly; 212. First side mold; 2121. Slide groove of sliding connection assembly; 2122. Slot of plug-in assembly; 2123. Fixing plate; 213. Second side mold; 2131. Arc mold; 21311. Horizontal pressure plate; 2132. Top plate; 214. Front mold; 2141. First splicing template; 2142. Second splicing template; 2143. Insert block of plug-in assembly; 215. Rear mold; 216. Reinforced side mold; 22. Pressure plate; 23. First adjustment device; 24. Second adjustment device; 25. Third adjustment device; 26. Fourth adjustment device; 3. Positioning and synchronous lifting device; 31. Lead screw; 4. Subway station base slab; 41. Base slab main body; 411. Bottom surface; 42. Pre-cast trench; 43. Tenon structure; 44. Arc structure. Detailed Implementation

[0020] To facilitate understanding of the present invention by those skilled in the art, specific embodiments of the present invention will be described below with reference to the accompanying drawings.

[0021] like Figure 1 As shown, the present invention proposes an integrated tenon molding equipment for casting tenon structures 43 on both ends of the main body 41 of the base plate, especially the tenon structure 43 at the end node of the cast-in-place base plate component in a subway station, including the equipment body, the positioning synchronous lifting device 3 and the casting mold device 2.

[0022] In the current construction process of the cast-in-place base slab 4, the entire prefabricated station base slab mold is laid out before the pouring is carried out. The forming requirements of the tenon structure at both ends are relatively strict. Therefore, during the cast-in-place construction, the cover mold needs to be strictly positioned with steel before the reinforcement is tied. However, during the process of laying the formwork, pouring and vibrating, it is still very likely that the cover molds at both ends 211 will be displaced or have changes in height. Therefore, this application first pours the main body of the base slab, leaving the post-pouring part at both ends of the base slab. After the strength of the middle pouring area reaches the standard and the equipment body can be installed, the upper part of both ends of the base slab is then precisely poured.

[0023] To better understand the technical solution of this invention, the structure of the subway station base plate 4 of this invention is now described. The subway station base plate 4 includes a pre-cast base plate main body 41 and multiple post-cast end node tenon structures 43 and 44 arc-shaped structural parts. Figure 2 As shown, the main body 41 of the base slab is the pre-cast portion, and a pre-cast trench 42 is provided near the side wall of the foundation pit on the main body 41 of the base slab. Figure 3 As shown, the tenon structure 43 and the arc structure 44 are post-cast parts formed by post-casting using a tenon integrated molding equipment. The material used for this part is ultra-high performance concrete (UHPC). Unlike post-cast ordinary concrete, which may have insufficient structural stress requirements, ultra-high performance concrete (UHPC) is a new type of cement-based composite material with high strength, high density, excellent durability, and high toughness.

[0024] By pouring ultra-high performance concrete into the end joints, the seismic performance and waterproofing performance of the connection joints can be improved, while also meeting the structural stress and construction requirements.

[0025] like Figures 4-13 The main components of the tenon-and-mortise integrated molding equipment are described below.

[0026] I. Equipment Body: The equipment body is movably connected to the base plate 41 and can move back and forth relative to the base plate 41. In this embodiment, the equipment body is a trolley 1, and a base plate track 1331 is laid along the construction axis of the base plate 41, allowing the trolley 1 to move along the track 1331. The trolley 1 includes multiple sets of steel frame modules 11 located in the middle, Γ-shaped modules 12 that are symmetrical on both sides and extend outward, and a travel and braking device 13.

[0027] The present invention uses a trolley 1 as the main body of the equipment. The trolley 1 has a low-space structure, simple construction, low height, adjustable span, but strong load-bearing capacity, and is safe and reliable. It can pass well in underground spaces with large foundation pit depths, which can reduce cross-interference operations in the three-dimensional space of the construction site and facilitate avoidance of the upper support structure.

[0028] Both the steel frame module 11 and the Γ-shaped module 12 are modular designs. During construction, the number of steel frame modules 11 can be adjusted according to site requirements, thereby achieving adjustable span.

[0029] Specifically, the outer end of the Γ-shaped module 12 of the trolley 1 is equipped with a top surface elevation monitoring device 121 to control the elevation of the cover plate. In this embodiment, four top surface elevation control devices are set, located at the front and rear ends of the top of the Γ-shaped modules 12 on both sides, to realize real-time monitoring of the elevation of the cover plate assembly.

[0030] The measurement principle of the top surface elevation monitoring device is as follows: control points are laid out on the left and right sides of the existing cast-in-place structure slab at both ends of the station assembly section. The top surface elevation monitoring device monitors the template elevation data and calculates the height difference with the control points to achieve accurate control of the template elevation.

[0031] When the top elevation control device detects a deviation in elevation, it activates the positioning synchronous lifting device 3 to move the mold assembly 21 up and down along the lead screw 31 until it is fixed at the elevation position. Then, it adjusts the side mold installation of the mold assembly 21.

[0032] In one embodiment, the top surface elevation control device is an electronic level, which is electrically connected to the controller. The electronic level enables high-precision, automated elevation measurement.

[0033] The mold components 21 on both sides of the trolley 1 can be adjusted on one side or both sides simultaneously. The control method can be adjusted by the controller. The control method and control principle are well known in the field. The specific parameters and working principle can be set according to the actual situation, and will not be elaborated here.

[0034] A cantilever frame 122 is fixedly installed at the lower part of the U-shaped module 12 of the trolley 1, and the positioning and synchronous lifting device 3 is fixedly installed on the cantilever frame 122. The cantilever frame 122 is welded from I-beams to ensure load-bearing stability.

[0035] After the modules of trolley 1 are assembled in the factory and transported to the site, they are fixedly connected as a whole by flanges. The upper part of trolley 1 is covered with steel plates. The number of steel frame modules 11 can be increased or decreased according to the span requirements of the foundation pit, so as to achieve adjustable span. The upper part of the U-shaped module 12 of trolley 1 is symmetrically suspended and mounted with positioning and synchronous lifting devices 3. The lower part of the positioning and synchronous lifting device 3 is detachably connected to the casting device 2. The bottom of trolley 1 has a driving and braking device 13 that can control the progress of trolley 1.

[0036] The traveling and braking device 13 includes a driving device and a driven device. The driving device includes a power unit 131 fixed to the trolley 1 and a gear and rack mechanism 132 connected to the power unit. The driven device is located at the bottom of the trolley 1 and includes a pulley and slide rail mechanism 133. The power unit 131 can be an electric motor or other existing equipment for providing power. The output end of the power unit is connected to the gear in the gear and rack mechanism 132. The rack 1321 of the gear and rack mechanism 132 is installed inside the base plate track 1331. The pulleys of the pulley and slide rail mechanism 133 are fixed to the bottom of the trolley 1, and the slide rails of the pulley and slide rail mechanism 133 are fixed to the base plate track 1331. The pulley and slide rail mechanism 133 has multiple pulleys, which can not only ensure forward and backward movement under the drive of the driving device, but also serve as a support device to support the trolley 1 on the track 1331.

[0037] The power unit 131 drives the gear of the gear and rack mechanism 1321 to move relative to the rack 1321, which in turn drives the pulley of the pulley and rail mechanism 133 to move relative to the rail, thereby realizing the movement of the trolley 1 relative to the base plate body 41.

[0038] The upper surface of the trolley 1 can be used to place a secondary pump truck. Through the hollow structure 123 in the middle of the Γ-shaped modules 12 on both sides of the trolley 1, it is convenient for the pump truck to pour concrete on both sides at the same time.

[0039] Through the structural design of the traveling and braking device 13 on the trolley 1, the meshing of the gear and rack mechanism 1321 enables the trolley 1 to move back and forth along the track 1331, reducing the possibility of slippage during the movement of the trolley 1. The controller controls the operation of the drive device, and the trolley 1 moves back and forth synchronously and stops synchronously on the tracks 1331 on the left and right sides, achieving precise control of the movement or stopping of the trolley 1. This ensures that the positions of the two casting devices 2 on both sides can be precisely moved to the designed positions without the need for extra correction work, reducing the error in the front and rear ring spacing caused by displacement uncertainty.

[0040] II. Positioning and Synchronous Lifting Device 3: The positioning and synchronous lifting device 3 is connected to the cantilever frame 122 of the U-shaped module 12 and moves up and down relative to the base plate body 41. The positioning and synchronous lifting device 3 is configured as a linkage-type lifting machine. In this embodiment, the positioning and synchronous lifting device 3 is a linkage-type screw jack, but it can also be other existing linkage-type lifting machines, such as a linkage electric reduction lifting machine. The linkage-type screw jack is prior art, and its structure and working principle will not be described in detail here.

[0041] During operation, the controller controls the screw of the linkage screw jack to move up and down, which in turn drives the mold assembly 21 to move up and down synchronously.

[0042] III. Casting Device 2: The casting device 2 is connected to the lower part of the positioning and synchronous lifting device 3 and can move up and down synchronously with the positioning and synchronous lifting device 3. The casting device 2 includes a mold assembly 21 and a pressure plate 22. The positioning and synchronous lifting device 3 is detachably connected to the pressure plate 22, and the pressure plate 22 is welded to the mold assembly 21.

[0043] The mold assembly 21 includes a cover mold 211, a first side mold 212, a second side mold 213, a front mold 214, and a rear mold 215. The cover mold 211 is fixedly connected to the front mold 214 and the rear mold 215, movably connected to the first side mold 212, and fixedly connected to the second side mold 213. The first side mold 212 is movably connected to the front mold 214 and the rear mold 215.

[0044] The cover mold 211 is made of high-strength channel steel plate. In this embodiment, the cover mold 211 has two parallel vertical plates near the front and rear mold ends. These vertical plates are connected to the first side mold, the front mold, and the rear mold, respectively. The upper surface of the cover mold 211 is also provided with multiple sets of protrusions 2111 for precisely shaping the tenon structure 43. The multiple sets of protrusions 2111 enable simultaneous pouring of multiple rings. A pouring window is opened at the upper end of the protrusions 2111 to facilitate the pouring of ultra-high performance concrete. The position is fixed by a positioning synchronous lifting device 3.

[0045] This invention utilizes post-cast ultra-high performance concrete (UHPC). The mold assembly 21 contains a mold for casting multi-ring tenon structures 43. The casting device performs simultaneous multi-ring casting instead of casting one ring at a time, improving work efficiency and reducing gaps between rings during later casting. It also provides excellent seismic and waterproof performance. Furthermore, since not all molds are laid out before casting, the process precision can be controlled and fine-tuned at any time, avoiding errors caused by operations during construction. Additionally, prefabricated structures have numerous joints, which are weak points in the seismic and waterproof performance of station structures. Due to the superior performance of UHPC material, post-casting UHPC at the upper ends of both sides of the cast-in-place components of the subway station improves the load-bearing performance of the structural nodes at the bottom slab ends. The tenon joints formed by UHPC enhance the load-bearing and waterproof performance, thereby increasing the overall durability of the structure.

[0046] Furthermore, two positioning pin sleeves 2112 are fixed along the length of the inner side of the casting window of the protrusion 2111 to form pre-reserved positioning pin holes for the precast components. During the later assembly construction, the corresponding side walls have positioning pin holes. Before installing the side walls, the positioning pins are installed in the positioning pin holes of the base plate, which makes it easier for the precast side walls to be inserted into the base plate through the positioning pins, making the installation more precise, faster, and more secure.

[0047] Because the elevation accuracy of the first-cast base slab 41 is low, and the sides of the first-cast base slab 41 have reserved areas for subsequent casting, the height of the subsequent casting on both sides may be inconsistent. Therefore, after the cover mold 211 of the subsequent casting reaches the design elevation, the first side mold 212 is set to be movably connected to the cover mold 211, specifically, it is a vertically sliding connection. The first side mold 212 can be adjusted up and down appropriately according to the reserved height of the subsequent casting, so that it can fully contact the already cast part of the bottom surface 411, thereby ensuring the accurate dimensions of the entire subsequent casting part. The sliding of the first side mold 212 can realize the casting of components of different heights to adapt to different height differences.

[0048] Specifically, if the reserved post-cast portion is thick, the first side mold 212 needs to be slid downward by the first adjustment device 23 with telescopic function, which is fixedly installed on the side wall of the first side mold 212.

[0049] Furthermore, the first side mold 212 and the cover mold 211 are slidably connected by a sliding connection assembly, and the first side mold 212 is connected to the front / rear molds by an insertion assembly. In one embodiment, the sliding groove 2121 of the sliding connection assembly and the slot 2122 of the insertion assembly are disposed on the first side mold 212, the slider 2113 of the sliding connection assembly is disposed on the cover mold 211, and the insert block 2143 of the insertion assembly is disposed on the front mold 214 and the rear mold 215, respectively.

[0050] Working process: The first adjusting device 23 is activated to drive the first side mold 212 to slide until the lower end of the first side mold 212 is in close contact with the bottom surface 411. Then, the second adjusting device 24 is fixed to the side wall of the foundation pit. At this time, the first adjusting device 23 and the second adjusting device 24 work simultaneously to fix and support the first side mold 212 and the cover mold 211. Then, the front mold 214 and the rear mold 215 are movably connected to the lower front and rear ends of the cover mold 211.

[0051] The front mold 214 and the rear mold 215 have the same structure, including at least one splicing template. Adjacent splicing templates are detachably connected, which is bolted in this embodiment. Specifically, if the reserved post-cast part is thick, multiple splicing templates are required for splicing.

[0052] When casting the tenon structure for the first and last rings, the front and rear mold end faces located at the front and rear ends of the base plate body 41 need to be fixed by a fourth adjustment device 26 to provide lateral support.

[0053] In one specific embodiment, the first splicing template 2141 is connected to the cover mold 211 and the arc mold 2131 of the second side mold 213 by bolts. After it is fixed, if the mold does not contact the bottom surface 411, the second splicing template 2142 is installed according to the actual thickness required for the lower end to be poured, and so on, until it contacts the bottom surface 411. This can flexibly adapt to the situation of inconsistent elevation of the main body of the base plate, without the need for high-precision pouring construction of the base plate, and has strong tolerance for construction deviations of the cast-in-place base plate.

[0054] Specifically, when adjusting from the thicker post-cast area to the thinner pre-cast area, the first adjustment device 23 needs to drive the first side mold 212 upward to slide upward until the bottom of the first side mold 212 just touches the bottom surface 411.

[0055] The second side mold 213 is located on the other side of the cover mold 211, and includes a top plate 2132 and an arc mold 2131. The top plate 2132 is fixedly connected to the cover mold 211 and is located on the same horizontal plane. The arc of the arc mold 2131 is the same as the arc of the base plate body 41. A third adjustment device 25 with telescopic function is provided between the top plate 2132 and the arc mold 2131 to provide vertical support force.

[0056] The arc-shaped mold 2131 is used to adapt to the arc-shaped structure 44 formed on the inner side of the base plate body 41. The bottom end of the arc-shaped mold 2131 is a horizontal pressure plate 21311 used to connect the third adjustment device 25. Specifically, the upper end of the horizontal pressure plate 21311 is a pressure plate 22, and several third adjustment devices 25 are provided on the upper end of the pressure plate 22 for fixing and supporting the top plate 2132.

[0057] To ensure the waterproofing of the precast structure by installing waterproof sealant strips on the side walls later, the upper end of the first splicing template 2141 has a first groove to facilitate the formation of the groove in the later-cast portion. The lower end of the first splicing template 2141 is provided with a tenon / groove for connecting with the fitting part of the second splicing template 2142, and the end connecting with the first side mold 212 is provided with a plug block 2143 of the plug-in component, which is adapted to the slot 2122 of the plug-in component provided at the corresponding end of the first side mold 212.

[0058] The second splicing template 2142 is connected to the arc-shaped template 2131 by bolts. The upper end is provided with a concave / convex tenon for connecting with the first splicing template 2141. The end connected to the first side template 212 is provided with a plug block 2143 of the plug-in component, which is adapted to the slot 2122 of the plug-in component provided at the corresponding end of the first side template 212.

[0059] Specifically, when installing the first splicing template 2141 and the second splicing template 2142, the plug block 2143 of the plug-in component is first inserted into the slot 2122 of the plug-in component, and then connected to the cover mold 211 and the arc mold 2131 by bolts. When disassembling the mold, the bolt connection must be removed first, and then the splicing template is taken out from the slot.

[0060] Specifically, the bottom of the lifting screw 31 of the positioning synchronous lifting device 3 is detachably connected to the pressure plate 22 via a flange. This connection can be electromagnetic adsorption or bolted. If electromagnetic adsorption is used, one of the flange and pressure plate 22 is set as an electromagnet, and the other as a permanent magnet. The controller controls whether the electromagnet is energized to achieve the magnetic connection. The positioning synchronous lifting device 3 has at least 2n+2 screws, where n is the number of rings installed in the prefabricated subway station, enabling precise four-way adjustment of the template. This device allows for the simultaneous casting of multiple rings of the prefabricated subway station base slab, reducing the seams between the front and rear rings of the base slab. Specifically, in one embodiment, the synchronous casting of the tenon structure consists of 3 sets, the positioning synchronous lifting device 3 has at least 8 screws, and the prefabricated subway station has 3 rings installed.

[0061] In one embodiment, the first, second, third and fourth adjusting devices are telescopic cylinders, and their movement is controlled by a hydraulic workstation configured inside the equipment. The control method is existing technology and will not be described in detail here.

[0062] like Figure 14 As shown, the present invention also proposes a construction process for a subway station base slab, applied to the subway station base slab 4 mentioned in the present invention, specifically including the following steps: Step 1: Tie the reinforcing bars and pour the main body of the base slab 41, in which the upper part of both sides of the bottom surface 411 is reserved for the post-pouring part and the reinforcing bars of the post-pouring part.

[0063] Step 2: After the strength of the middle pouring area of ​​the base plate body 41 reaches the standard, the base plate track 1331 is laid according to the construction axis. The base plate track 1331 is used to connect the movable trolley 1.

[0064] Step 3: The casting device 2 is fixed to the lower part of both ends of the equipment body by the positioning and synchronous lifting device 3. The positioning and synchronous lifting device 3 is fixed on the cantilever frame 122 of the lower middle layer of the U-shaped module 12. The bottom of the lead screw 31 of the positioning and synchronous lifting device 3 is connected to the pressure plate 22 to complete the installation of the casting device 2.

[0065] The prefabricated steel frame module 11 and the Γ-shaped module 12 with the casting device 2 installed are assembled on site by flange splicing to form the trolley 1. At the same time, the driving and braking device 13 is assembled with the trolley 1. The number of intermediate frame modules can be adjusted according to the site requirements, so as to achieve adjustable span.

[0066] Step 4: The height of the cover mold 211 of the mold assembly 21 is monitored in real time by the top surface elevation monitoring device 121. The controller adjusts the vertical movement of the positioning synchronization device to drive the mold assembly 21 to move synchronously to adjust the elevation to the design position.

[0067] Step 5: Adjust and secure mold assembly 21: Side mold installation and elevation adjustment: The pressure plate 22 at the bottom of the arc-shaped mold 2131 and the cover mold 211 are adjusted by the third adjustment device 25 to flatten the horizontal pressure plate 21311 with the bottom end, and the cover mold 211 is kept at the elevation position. The support assembly is fixed by the third adjustment device 25 to fix the bottom horizontal pressure plate 21311, and at the same time, the horizontal structure of the cover mold 211 itself is stabilized.

[0068] Fixed plates 2123 extend from both ends of the first side mold 212. The first adjustment device 23 installed at the lower end of the fixed plate 2123 drives the first side mold 212 to slide downward and adjust it to contact the bottom surface 411 of the poured fertilizer tank. The second adjustment device is located between the first side mold 212 and the side wall of the foundation pit for fixed support.

[0069] The first splicing template 2141, which is connected to the lower end of the front face of the cover mold 211, is first connected to the first side mold 212 by a plug-in assembly. The first splicing template 2141 is connected to the front face of the cover mold 211 by bolts and to one end of the arc mold 2131 by bolts. By setting concave / convex tenons on the upper and lower end faces, it can be spliced ​​with other connected connecting parts, which can both ensure the tightness of the original components and play a limiting role.

[0070] The second splicing template 2142 can be spliced ​​sequentially as needed. The front and rear ends of the cover mold 211 are coated with a release agent.

[0071] After adjustment, the elevation of the mold assembly 21 is confirmed by the top surface elevation monitoring device 121.

[0072] Step 6: The secondary pump truck pours ultra-high performance concrete into the pouring window above the mold assembly 21: The secondary pump truck directly pours concrete into the window above the protrusion 2111 above the cover mold 211 through the hollow structure 123 in the middle of the module. Furthermore, the subsequent pouring part is made of ultra-high performance concrete (UHPC). The bond strength between UHPC and the pre-embedded steel bars is far greater than that of ordinary concrete, which can significantly improve the anchorage efficiency of the steel bars, reduce stress concentration in the joint area, and enhance the durability and waterproofness of the structure.

[0073] Step 7: The controller controls the positioning synchronous lifting device 3 to retract, and the positioning synchronous lifting device 3 separates from the pressure plate 22 of the casting device 2. The casting device 2 remains in place to wait for the subsequent casting part to cure and form. The controller controls the operation of the travel and braking device 13 of the equipment body. The travel and braking device 13 drives the equipment body to move to the preset displacement value and then stops.

[0074] Specifically, the bottom of the lifting screw 31 of the positioning synchronous lifting device 3 is separated from the pressure plate 22. The preset displacement value is input by the controller, and the drive device drives the trolley 1 forward a certain distance and then stops. The meshing of the gear and rack mechanism 1321 ensures that the trolley 1 does not slip during its movement, so that the trolley 1 can reliably and smoothly travel to the second design position. At the same time, the displacement is accurate, ensuring that the symmetry accuracy on both sides is not deviated.

[0075] Step 8: The trolley 1 is moved to the next group of areas to be poured. The bottom of the screw 31 of the positioning synchronous lifting device 3 is raised. Then, a new set of pouring mold device 2 is configured. Steps 3 to 5 are repeated to continue pouring the next group. And so on.

[0076] Step 9: After the post-pouring section has cured and formed, the trolley 1 returns under the control of the controller, the constraints are released, and the mold assembly 21 is demolded. The demolded casting device can then be used for the next set of pours.

[0077] Specifically, the pressure plate 22 at the upper end of the cover mold 211 is connected to the bottom of the lifting screw 31. The first, second, and third adjusting devices retract, and the positioning synchronous lifting device 3 adjusts the lifting screw 31 to drive the entire casting device to be lifted and separated from the post-casting part. After demolding, the mold is coated with a release agent and then used in subsequent casting processes.

[0078] The advantages of this invention are: 1. The present invention selects a trolley 1 as the main body of the equipment. The trolley 1 has a low-space structure, simple construction, low height, adjustable span, but strong load-bearing capacity, and is safe and reliable. It can pass well in underground spaces with large foundation pit depths, reduce interference between upper and lower spaces, reduce three-dimensional cross operations on the construction site, and facilitate avoidance of upper support structures.

[0079] 2. This invention utilizes post-cast ultra-high performance concrete (UHPC). The mold assembly 21 contains a multi-ring tenon structure 43. The casting device involves simultaneous casting of multiple rings instead of individual rings, improving work efficiency and reducing gaps between rings during later casting. It also provides excellent seismic and waterproof performance. Furthermore, since not all molds are laid out before casting, the process precision can be controlled and fine-tuned at any time, avoiding errors caused by operational procedures during construction. Additionally, prefabricated structures have numerous joints, which are weak points in the seismic and waterproof performance of station structures. Due to the superior performance of UHPC material, post-casting UHPC at the upper ends of both sides of the cast-in-place components of the subway station improves the load-bearing capacity of the structural nodes at the bottom slab ends. The tenon joints formed by UHPC enhance the load-bearing and waterproof performance, thereby increasing the overall durability of the structure.

[0080] 3. This invention uses the top surface elevation monitoring device 121 to provide feedback monitoring data, and then precisely adjusts and controls the top surface elevation of the positioning synchronous lifting device 3 during pouring. This enables precise adjustment of the height of the symmetrical two-sided cover mold 211, ensuring that the top elevations of the two sides of the cast-in-place component are consistent. This reduces the instability of the entire ring subway component structure caused by inconsistent left and right, upper and lower elevations during assembly. It also reduces the vertical height difference between adjacent blocks in the front and rear rings, ensuring the precision of the connection with the prefabricated walls of the subway station, and improving the normal operation and service life of the prefabricated subway station throughout its entire life cycle.

[0081] 4. This invention utilizes the structural design of the traveling and braking device 13 of the trolley 1. Through the meshing of the gears in the gear and rack mechanism 1321 with the toothed track 1331, the trolley 1 moves back and forth along the track 1331, reducing the possibility of slippage during movement. The left and right sides of the trolley 1 move back and forth synchronously on the track 1331, and simultaneously come to a stop, achieving precise control of the trolley 1's movement and stopping. This ensures that the positions of the two side casting devices 2 can be precisely moved to their designed positions without unnecessary correction work, reducing errors in the front and rear ring spacing caused by displacement uncertainty.

[0082] 5. This invention reduces the need for hoisting equipment with large foundation pit depths by setting up a suspended construction trolley 1. The device can be constructed section by section. The tenon integrated forming device can be cast in one pour for multiple rings, which reduces the excessive error caused by too many gaps in the subway station base plate 4 ring by ring, and prevents excessive longitudinal misalignment of adjacent blocks in each ring during the assembly and construction process.

[0083] 6. The casting device 2 of the present invention is movably connected to the trolley 1. The trolley 1 can move back and forth. One trolley 1 is equipped with multiple sets of mold components 21. When the trolley 1 has finished casting and curing and is ready for demolding, the trolley 1 can return to remove the first set of mold components 21 after casting and curing, and reuse them in the casting process. Then, the demolding and reuse are repeated in sequence, which reduces the investment of molds, ensures the continuity of the construction process, and does not cause the molds to be idle. At the same time, it is not necessary to install steel brackets inside in advance when the steel bars are tied, which reduces the use of steel.

[0084] The embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A tenon integrated molding apparatus, characterized by, The mortise structure for casting on the bottom plate body comprises: The device body is movably connected to the bottom plate body and moves forward and backward relative to the bottom plate body; The positioning synchronous lifting device is connected to the end of the device body and moves up and down relative to the bottom plate body; The mold pouring device is connected to the lower part of the positioning synchronous lifting device; the mold pouring device comprises a mold assembly and a pressing plate, the positioning synchronous lifting device is connected to the pressing plate, and the pressing plate is connected to the mold assembly; the device body is provided with a top surface elevation monitoring device for monitoring the height of the mold assembly; The controller is used for adjusting the positioning synchronous lifting device according to the data of the top surface elevation monitoring device, and the positioning synchronous lifting device drives the pressing plate and the mold assembly to move synchronously.

2. The mortise-integrated forming apparatus according to claim 1, wherein The device body comprises a plurality of steel skeleton modules, Γ modules symmetrically arranged at both ends, and a running and braking device; the top surface elevation monitoring device is arranged on the outer side of the Γ module; and the Γ module is connected to the mold pouring device at the lower part.

3. The mortise-integrated forming apparatus according to claim 2, wherein The running and braking device comprises a driving device and a driven device; the driving device comprises a power device fixed to the device body and a gear and rack mechanism connected to the power device; and the driven device is arranged at the bottom of the device body and comprises a pulley and slide rail mechanism. The power device drives the gear of the gear and rack mechanism to move relative to the rack, synchronously drives the pulley of the pulley and slide rail mechanism to move relative to the slide rail, and realizes the movement of the device body relative to the bottom plate body.

4. The mortise-integrated forming apparatus according to claim 1, wherein The mold assembly comprises a cover mold, a first side mold, a second side mold and a front / rear mold; the cover mold is fixedly connected with the front / rear mold, movably connected with the first side mold and fixedly connected with the second side mold; and the first side mold is movably connected with the front / rear mold. A plurality of groups of protruding parts are formed on the upper surface of the cover mold, and a pouring window is formed at the upper end of each protruding part. The first side mold is provided with first and second adjusting devices with telescopic function; the first adjusting device abuts against the top surface of the poured trench and is used for driving the vertical movement of the first side mold; and the second adjusting device abuts against the side wall of the foundation pit and is used for providing lateral support force for the first side mold. The second side mold comprises a top plate and an arc-shaped mold; the top plate is fixedly connected with the cover mold and located at the same horizontal plane; the arc of the arc-shaped mold is the same as the arc of the bottom plate body; and a third adjusting device with telescopic function is arranged between the top plate and the arc-shaped mold to provide vertical support force.

5. The mortise-integrated forming apparatus according to claim 4, wherein At least one positioning pin sleeve is fixed inside the pouring window along the length direction.

6. The mortise-integrated forming apparatus according to claim 4, wherein The mold assembly further comprises a sliding connection assembly and a plug-in assembly; the first side mold is slidably connected with the cover mold through the sliding connection assembly; and the first side mold is plug-in connected with the front / rear mold through the plug-in assembly.

7. The mortise-integrated forming apparatus according to claim 4, wherein The front / rear mold comprises at least one spliced mold plate; adjacent spliced mold plates are detachably connected; the end surface of the front / rear mold located at the first ring and the tail ring poured on the bottom plate body needs to be fixed by a fourth adjusting device with telescopic function to provide lateral support.

8. The mortise-integrated forming apparatus according to claim 1, wherein The positioning synchronous lifting device comprises a linkage type elevator; the linkage type elevator is a linkage type lead screw elevator; the number of lead screws is at least 2n+2, and n is the number of rings in one assembly of the assembled subway station.

9. A subway station floor, characterized in that The base plate includes a main body, and also includes a tenon structure and an arc structure cast using the tenon-tenon integrated molding device as described in any one of claims 1 to 8; after the main body of the base plate is cast, the tenon structure and the arc structure are cast using the tenon-tenon integrated molding device.

10. A construction process for a subway station floor, characterized in that, The method of application to the subway station base plate as described in claim 9 includes the following steps: S1. Reinforcing bar binding, pouring the main body of the base slab, with reserved post-cast portions and reinforcing bars at both ends; S2. After the main body of the base plate meets the strength requirements, the base plate track is laid according to the construction axis. The base plate track is used to connect the equipment body and assemble the equipment body. S3. The casting device is fixed to the lower part of both ends of the equipment body by a positioning and synchronous lifting device; S4. The height of the mold assembly is monitored in real time by the top surface elevation monitoring device, and the controller adjusts the vertical movement of the positioning synchronization device to drive the mold assembly to move synchronously to adjust the elevation to the design position; S5. Adjust the vertical height of the side mold of the mold assembly. After fixing the mold assembly, confirm the elevation of the mold assembly again through the top surface elevation monitoring device to ensure the elevation is accurate. S6. The secondary pump truck pours ultra-high performance concrete into the pouring window above the mold assembly; S7. The controller controls the positioning synchronous lifting device to retract, the positioning synchronous lifting device separates from the pressure plate of the casting device, and the casting device remains in place to wait for the subsequent casting part to cure and form; the controller controls the operation of the travel and braking device of the equipment body, and the travel and braking device drives the equipment body to move to the preset displacement value and then stops. S8. Repeat steps S3 to S5 to continue pouring the next set; S9. After the post-pouring section has been cured and formed, the equipment body returns under the control of the controller, the constraints are removed, the mold assembly is demolded, and the demolded casting device continues to be used for the next set of castings.

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