Three-limb steel frame base pre-embedding tool of integrated intelligent monitoring system and construction method of three-limb steel frame base pre-embedding tool

Abstract

The invention relates to the technical field of tunnel construction, in particular to a three-limb steel frame base embedding tool of an integrated intelligent monitoring system and a construction method. The tool comprises a foldable triangular support formed by connecting a first supporting column and a second supporting column through a hinge, and the unfolding posture of the foldable triangular support is fixed through a plug pin locking mechanism. The tool is integrated with an intelligent monitoring system composed of an angular displacement sensor, an infrared distance measuring sensor, a red-green double-color indicator lamp and a microcontroller, the unfolding angle and key structure size of the tool can be monitored in real time, a green light is automatically turned on to prompt the tool to be in place when a measured value is within a preset threshold range, and otherwise, a red light is turned on to give an alarm; during construction, the tool is fixed to an inverted arch trestle formwork, the tool is connected with a three-limb steel frame base through high-strength bolts after being unfolded and locked, the in-position state is judged according to an indicator lamp, and disassembly and recovery are conducted after concrete pouring; the tool has the advantages of high precision, high efficiency, intelligent monitoring, safe operation, reusability and the like, and is suitable for tunnel engineering with severe environment and high standard requirements.

Description

Technical Field

[0001] This invention relates to the field of tunnel and underground engineering construction technology, and more specifically, to a construction tool and method for accurately pre-embedding the support structure connection base in tunnel lining concrete, particularly a reusable pre-embedding tool system with real-time intelligent monitoring and visual feedback functions. Background Technology

[0002] In the construction of underground engineering projects such as railway and highway tunnels, the precise pre-embedding of three-limb steel frame bases within the invert arch or sidewall lining is a crucial prerequisite for the subsequent installation of support steel frames and the formation of a stable support system. Traditional pre-embedding methods typically follow a process of "manual measurement and layout—drilling holes—inserting reinforcing bars—leveling with string lines—welding and fixing the base." This method has significant drawbacks: First, the process chain is long, entirely reliant on manual operation, resulting in low efficiency and high labor intensity; second, errors are easily introduced at each stage, especially in the final welding and fixing stage, which is greatly affected by the operator's skill level, making it difficult to guarantee a uniform elevation, planar position, and verticality of the pre-embedded base, leading to large fluctuations in construction quality; third, the entire process lacks real-time, objective verification methods, and quality often depends on post-construction measurements, with problems discovered after concrete has already been poured, resulting in high correction costs; finally, using welding to fix the base to the reinforcing bars means the tooling cannot be reused, and welding fumes and arc light pollution are generated, which does not meet the requirements of green construction.

[0003] In recent years, although some positioning fixtures aimed at improving efficiency have emerged, such as simple support frames, these fixtures typically only solve the "support" problem and do not address the core challenge of "precise positioning and real-time verification." After the fixtures are in place, technicians still need to perform tedious measurements and verifications using tools such as total stations, levels, and straightedges. In the harsh environment of tunnels, with insufficient light, limited space, and significant mechanical interference, measurements are difficult and inefficient, and there is still a risk of human error. Therefore, there is an urgent need for an intelligent pre-embedded solution that integrates rapid positioning, automatic monitoring, real-time feedback, and reusability to fundamentally improve the accuracy, efficiency, reliability, and standardization of tunnel pre-embedded construction. Summary of the Invention

[0004] The purpose of this invention is to provide a pre-embedded tooling and construction method for a three-limb steel frame base of an integrated intelligent monitoring system in order to solve the above-mentioned problems.

[0005] The present invention achieves the above objectives through the following technical solutions:

[0006] A three-limb steel frame base embedded tooling for an integrated intelligent monitoring system includes a first column and a second column, which are connected by a hinge to form a foldable support structure.

[0007] Angle steel cross brace, which is welded to the upper end of the second column;

[0008] Two angle steel positioning braces are welded to both ends of the angle steel cross brace, and the ends of the two angle steel positioning braces away from the angle steel cross brace are welded to each other, forming a stable triangular truss together with the first column, the second column and the angle steel cross brace.

[0009] The pin locking mechanism includes a locking plate disposed on the first support column, a row of toothed pin holes disposed on the second support column, and a pin. When the second support column is rotated to the working position, the pin passes through the locking plate and is inserted into the corresponding toothed pin hole to achieve mechanical locking.

[0010] The connection interface is a bolt connection hole opened on the angle steel positioning brace, which is used for detachable connection with the three-limb steel frame base by high-strength bolts;

[0011] The base plate, which is welded to the bottom end of the first support column, is used for fixed connection with the arch bridge template;

[0012] The intelligent monitoring system includes an angular displacement sensor installed at the hinge pivot, an infrared distance sensor installed on the lower surface of the angle steel positioning brace, a red-green dual-color indicator light installed on the upper surface of the angle steel positioning brace, and a microcontroller electrically connected to the angular displacement sensor, the infrared distance sensor, and the red-green dual-color indicator light respectively; the microcontroller is preset with an angle qualification threshold and a distance qualification threshold, and is used to control the color display of the red-green dual-color indicator light according to the sensor signal.

[0013] Preferably, the first and second pillars are made of I-beams.

[0014] Preferably, the angular displacement sensor is a conductive plastic potentiometer or an encoder.

[0015] Preferably, the angle qualification threshold is the design working angle value ±0.5°, and the distance qualification threshold is the design distance value ±10mm.

[0016] Preferably, when the real-time angle value monitored by the angular displacement sensor and the real-time distance value monitored by the infrared ranging sensor are both within their respective qualified threshold ranges, the microcontroller controls the red-green dual-color indicator light to emit a solid green light; otherwise, it controls it to emit a flashing red light.

[0017] Preferably, the base plate is a steel plate with mounting holes.

[0018] Preferably, the high-strength bolt is a grade 10.9 bolt.

[0019] A construction method using the pre-embedded fixtures described above includes the following steps:

[0020] S1: Weld and fix the base plate of the pre-embedded tooling at the preset position of the arch bridge template;

[0021] S2: Unfold the first and second pillars, rotate the second pillar to the working position, and insert the pin to complete the locking;

[0022] S3: Place the three-limb steel frame base on the angle steel positioning brace and fasten it by high-strength bolts passing through the bolt connection holes;

[0023] S4: Observe the color of the red and green dual-color indicator light. If it shows green, the positioning is deemed qualified; if it shows red, adjust the tooling posture until the indicator light turns green.

[0024] S5: After the concrete is poured and reaches its strength, remove the high-strength bolts, pull out the pins, and fold and recycle the embedded tooling.

[0025] Preferably, in step S4, if a red light is displayed, the adjustment method includes checking and ensuring that the pin is fully in place, adjusting the flatness of the three-limb steel frame base, or removing obstacles on the sensor measurement path.

[0026] Preferably, the pre-embedded tooling is transferred along with the arch bridge formwork to the next construction cycle for reuse.

[0027] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0028] 1. By integrating angular displacement sensors and infrared ranging sensors, real-time and automatic monitoring of the tooling unfolding angle and key installation dimensions is achieved. Combined with preset thresholds and intuitive feedback from red and green dual-color indicator lights, human measurement errors and subjective misjudgments are effectively avoided, ensuring that the elevation, planar position and verticality of the three-limb steel frame base are accurately positioned in one go.

[0029] 2. The tooling adopts a foldable design and a pin-type mechanical locking, which makes unfolding and locking quick and easy; the base is detachably connected by high-strength bolts, making installation convenient; the intelligent monitoring system realizes automatic verification, replacing the traditional cumbersome manual layout, measurement and verification process, significantly shortening the process time and reducing labor intensity;

[0030] 3. The real-time monitoring and instant feedback mechanism keeps the construction process under control, eliminating the problem of discovering deviations only after completion and reducing rework and repair costs; the dual protection of mechanical locking and sensor threshold improves the stability and repeatability of tooling placement.

[0031] 4. The red and green dual-color indicator lights provide clear and intuitive status indications. Even in poor lighting and complex environments inside tunnels, workers can quickly determine whether the installation is qualified, reducing reliance on visual observation and instrument operation, and lowering safety risks and operational difficulty.

[0032] 5. The tooling adopts all bolted connections, which avoids the smoke and arc pollution caused by traditional welding processes and meets the requirements of green construction. The tooling is reusable and can be rotated with the arch bridge formwork to subsequent construction cycles, reducing material consumption and tooling amortization costs, resulting in significant economic benefits.

[0033] 6. The structure is simple, sturdy and durable, suitable for harsh construction environments inside tunnels; the intelligent system has a modular design, making installation and maintenance convenient, and is suitable for various tunnel and underground engineering projects that require high-precision pre-embedding, with good versatility and promotional value. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0035] Figure 1 This is a three-dimensional structural schematic diagram of the pre-embedded tooling for the three-limb steel frame base of the integrated intelligent monitoring system described in this invention;

[0036] Figure 2 for Figure 1 Enlarged view of point A in the middle;

[0037] Figure 3 This is a three-dimensional structural schematic diagram of the pre-embedded tooling for the three-limb steel frame base of the integrated intelligent monitoring system described in this invention, from another perspective.

[0038] Figure 4 for Figure 3 Enlarged view at point B in the middle;

[0039] Figure 5 Working principle diagram of the three-limb steel frame base pre-embedded tooling of the integrated intelligent monitoring system described in this invention;

[0040] The annotations in the attached figures are explained as follows:

[0041] 1. First support column; 2. Second support column; 3. Angle steel cross brace; 4. Angle steel positioning diagonal brace; 5. Hinge; 6. Pin; 7. Locking plate; 8. Toothed pin hole; 9. Bolt connection hole; 10. Base plate; 11. Inverted arch trestle formwork; 12. Three-limb steel frame base; 13. Angular displacement sensor; 14. Infrared distance sensor; 15. Red and green dual-color indicator light. Detailed Implementation

[0042] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. In addition, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0043] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation", "connection", and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this invention can be understood through the specific circumstances.

[0044] The present invention will be further described below with reference to the accompanying drawings:

[0045] Example 1

[0046] Reference Figures 1 to 4 This embodiment provides a pre-embedded tooling for a three-limb steel frame base 12 of an integrated intelligent monitoring system, including two Q235B I-beams as supports, namely a first support 1 and a second support 2, which are connected by a hinge 5; an angle steel cross brace 3 is provided at the upper end of the second support 2, which is a 10# angle steel and welded to the second support 2; angle steel positioning diagonal braces 4 are welded to both ends of the angle steel cross brace 3, and the ends of the two angle steel positioning diagonal braces 4 away from the angle steel cross brace 3 are welded together, which are two 8# angle steels.

[0047] The tooling also includes an intelligent detection system, which includes an angular displacement sensor 13, an infrared ranging sensor 14, a red-green dual-color indicator light 15, and a microcontroller. The microcontroller (not shown in the figure, but may be encapsulated inside or near the housing of the red-green dual-color indicator light 15) is connected to the angular displacement sensor 13, the infrared ranging sensor 14, and the red-green dual-color indicator light 15 via cables.

[0048] An angular displacement sensor 13 is coaxially mounted on the rotation axis of hinge 5. The angular displacement sensor 13 is a conductive plastic potentiometer or encoder, used to accurately measure the rotation angle α of the second pillar 2 relative to the first pillar 1. A locking plate 7 with a through hole is welded on the first pillar 1. A row of toothed pin holes 8 with arc-shaped edges is machined at the corresponding position of the second pillar 2. When the second pillar 2 rotates to the designed working position, the operator inserts a steel pin 6 into the hole of the locking plate 7 and a toothed pin hole 8 that is aligned with it. The tooling is then firmly locked. The sawtooth design can effectively prevent the pin from coming off under vibration.

[0049] An infrared ranging sensor 14 is installed on the lower surface of the angle steel positioning brace 4, and its transmitting / receiving window is vertically aligned with the surface of the inverted arch trestle template 11 below to measure the distance between it and the inverted arch trestle template 11; a red and green dual-color indicator light 15 is installed on the upper surface of the angle steel positioning brace 4.

[0050] Two bolt holes 9 are made on each of the two angle steel positioning braces 4. The three-limb steel frame base 12 is fastened to the angle steel positioning braces 4 through the corresponding holes on its base plate 10 using two 10.9 grade high-strength bolts, achieving rapid assembly. At the bottom end of the first support column 1, a steel plate with mounting holes is welded as the base plate 10. Before construction, the base plate 10 is accurately positioned and welded to the arch bridge formwork 11 by measurement and layout, thereby ensuring that the spatial position of all pre-embedded tools meets the design requirements.

[0051] like Figure 5 As shown, the working principle of the intelligent detection system is as follows: After the microcontroller is powered on, the angular displacement sensor 13 continuously outputs an electrical signal corresponding to the angle α, and the infrared ranging sensor 14 continuously outputs an electrical signal corresponding to the distance d. The microcontroller has preset acceptable thresholds, for example: the α threshold is 90° ± 0.5°, and the d threshold is the design value (e.g., 300mm) ± 10mm. The controller performs the following judgments in real time:

[0052] Conditional judgment: IF(89.5°≤α≤90.5°)AND(290mm≤d≤310mm)THEN

[0053] Execution result: Output drive signal, causing indicator light 15 to emit a solid green light.

[0054] Otherwise: Output drive signal to make the red-green dual-color indicator light 15 flash red light (alarm state).

[0055] The construction process is as follows:

[0056] Preparation and fixing: After the invert arch reinforcement is tied, according to the measurement results, the base plates 10 of multiple tools of the present invention are welded to the predetermined positions of the invert arch trestle formwork 11.

[0057] Unfolding and locking: Unfold the tooling in the folded state, rotate the second support 2 to approximately vertical, and insert the pin 6 to lock it;

[0058] Install the base: Hoist the three-limb steel frame base 12 onto the angle steel positioning brace 4, align the bolt connection holes 9, and tighten the high-strength bolts;

[0059] Intelligent verification: Workers observe the red and green dual-color indicator light 15; if it is green, it indicates that the angle and distance have been automatically verified and qualified, the pre-embedded work at this point is completed, and concrete pouring can be prepared immediately; if it is red, it is necessary to check whether the pin 6 is fully in place, whether the base is placed flat, or whether there are foreign objects blocking the sensor measurement path, and make fine adjustments (such as tapping the support) until the red and green dual-color indicator light 15 turns green.

[0060] Recycling and reuse: After the concrete strength of the inverted arch section reaches the required level, loosen the high-strength bolts to separate the tooling from the three-limb steel frame base 12 (which has been embedded in the concrete), pull out the pin 6, fold the tooling, and the inverted arch trestle template 11 with the invention can be transferred to the next cycle of use.

[0061] Example 2

[0062] The difference between this embodiment and embodiment 1 is that a locking plate 7 with a through hole is welded on the first support 1, and an elongated hole is machined at the corresponding position of the second support 2. The locking plate 7 is fixed to the position of the elongated hole by bolts. Fixing it with bolts makes it convenient to fine-tune the position in the elongated hole, and the adjustment accuracy is higher.

[0063] Hinges 5, arch bridge templates 11, three-limb steel frame bases 12, angular displacement sensors 13, infrared ranging sensors 14, red and green dual-color indicator lights 15, and microcontrollers are all general standard parts or components known to those skilled in the art. Their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods, so they will not be described in detail here.

[0064] The foregoing has shown and described the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are only illustrative of the principles of the present invention. Various changes and modifications can be made to the present invention without departing from the spirit and scope of the present invention, and all such changes and modifications fall within the scope of the present invention as claimed.

Claims

1. A pre-embedded tooling for a three-limb steel frame base of an integrated intelligent monitoring system, characterized in that, include: The first pillar (1) and the second pillar (2) are connected by a hinge (5) to form a foldable support structure. Angle steel cross brace (3) is welded to the upper end of the second column (2); Two angle steel positioning braces (4) are respectively welded to both ends of the angle steel cross brace (3), and the ends of the two angle steel positioning braces (4) away from the angle steel cross brace (3) are welded to each other, forming a stable triangular truss together with the first column (1), the second column (2) and the angle steel cross brace (3). The pin locking mechanism includes a locking plate (7) disposed on the first support (1), a row of toothed pin holes (8) disposed on the second support (2), and a pin (6). When the second support (2) is rotated to the working position, the pin (6) passes through the locking plate (7) and is inserted into the corresponding toothed pin hole (8) to achieve mechanical locking. The connection interface is a bolt connection hole (9) opened on the angle steel positioning brace (4), which is used to detachably connect to the three-limb steel frame base (12) by means of high-strength bolts; The base plate (10) is welded to the bottom end of the first support column (1) and is used to fix it to the arch bridge template (11); The intelligent monitoring system includes an angular displacement sensor (13) installed at the hinge (5) pivot, an infrared distance sensor (14) installed on the lower surface of the angle steel positioning brace (4), a red-green dual-color indicator light (15) set on the upper surface of the angle steel positioning brace (4), and a microcontroller electrically connected to the angular displacement sensor (13), the infrared distance sensor (14), and the red-green dual-color indicator light (15) respectively; the microcontroller is preset with an angle qualified threshold and a distance qualified threshold, which are used to control the color display of the red-green dual-color indicator light (15) according to the sensor signal.

2. The embedded tooling according to claim 1, characterized in that, The first support (1) and the second support (2) are made of I-beams.

3. The embedded tooling according to claim 1, characterized in that, The angular displacement sensor (13) is a conductive plastic potentiometer or encoder.

4. The embedded tooling according to claim 1, characterized in that, The acceptable angle threshold is the design working angle value ±0.5°, and the acceptable distance threshold is the design distance value ±10mm.

5. The embedded tooling according to claim 1, characterized in that, When the real-time angle value monitored by the angular displacement sensor (13) and the real-time distance value monitored by the infrared ranging sensor (14) are both within their respective qualified threshold ranges, the microcontroller controls the red-green dual-color indicator light (15) to emit a constant green light; otherwise, it controls it to emit a flashing red light.

6. The embedded tooling according to claim 1, characterized in that, The base plate (10) is a steel plate with mounting holes.

7. The embedded tooling according to claim 1, characterized in that, The high-strength bolts are grade 10.9 bolts.

8. A construction method using the pre-embedded fixture as described in any one of claims 1-7, characterized in that, Includes the following steps: S1: At the preset position of the arch bridge template (11), the base plate (10) of the pre-embedded tooling is welded and fixed; S2: Unfold the first support column (1) and the second support column (2), rotate the second support column (2) to the working position, and insert the pin (6) to complete the locking; S3: Place the three-limb steel frame base (12) on the angle steel positioning brace (4) and fasten it by high-strength bolts passing through the bolt connection hole (9); S4: Observe the color of the red and green dual-color indicator light (15). If it shows a green light, the positioning is qualified; if it shows a red light, adjust the tooling posture until the indicator light turns green. S5: After the concrete is poured and reaches its strength, remove the high-strength bolts, pull out the pin (6), and fold and recycle the embedded tooling.

9. The construction method according to claim 8, characterized in that, In step S4, if a red light is displayed, the adjustment methods include checking and ensuring that the pin (6) is fully in place, adjusting the flatness of the three-limb steel frame base (12), or removing obstacles on the sensor measurement path.

10. The construction method according to claim 8, characterized in that, The pre-embedded tooling is transported along with the arch bridge template (11) to the next construction cycle for reuse.

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