Line cutting and chiseling device for precast beam and construction method of line cutting and chiseling device

Abstract

The invention relates to the technical field of bridge construction, and particularly discloses a line cutting and chiseling device for a precast beam and a construction method of the line cutting and chiseling device. A mechanical arm is installed on the vehicle body, a first connecting end is arranged on the mechanical arm, and the scabbling system, the line cutting system and the dust removal system are each provided with a second connecting end; a central control system is installed in the vehicle body and connected to the mechanical arm. And the central control system is also connected to a scabbling system, a wire cutting system or a dust removal system which is connected with the first connecting end. The mechanical arm is used for switching the wire cutting system, the scabbling system and the dust removal system to work, the switching process is rapid, the efficiency can be improved, the mechanical arm controls the wire cutting system and the scabbling system to conduct steel strand cutting and anchor recess scabbling, and compared with manual operation, the construction efficiency is higher, and safety is higher.

Description

Technical Field

[0001] This invention relates to the field of bridge construction technology, specifically to a tangent and roughening device for precast beams and its construction method. Background Technology

[0002] In the construction of precast beams for bridges, the cutting of steel strands and the roughening of anchor holes are important procedures. The quality of the cutting and roughening directly affects the quality and stability of the entire prestressed system of the bridge.

[0003] Currently, steel strand cutting is mostly done manually using a grinding wheel cutter, and anchor hole roughening relies on manual roughening using a pneumatic hammer or electric pick. This method of operation is inefficient, time-consuming, and makes it difficult to guarantee the quality of steel strand cutting and anchor hole roughening, while also posing a high safety risk. Summary of the Invention

[0004] The purpose of this invention is to provide a tangent and roughening device for precast beams and its construction method to solve the problems mentioned in the background art.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A tangent and chiseling device for precast beams includes a vehicle body; a robotic arm is mounted on the vehicle body, and the robotic arm is provided with a first connecting end; a chiseling system, a tangent system, and a dust removal system are each provided with a second connecting end; the second connecting ends of the chiseling system, the tangent system, and the dust removal system are switchably connected to the first connecting end; a central control system is mounted in the vehicle body, and the central control system is connected to the robotic arm; the central control system is also connected to the chiseling system, the tangent system, or the dust removal system connected to the first connecting end.

[0006] Furthermore, the vehicle body is equipped with a bracket, and the top of the bracket has three sliding grooves; the chiseling system includes a telescopic robotic arm, the bottom of which is connected to an impact drill bit, and the top of the telescopic robotic arm is equipped with a disc, the diameter of which is larger than the width of the sliding groove, so that the telescopic robotic arm is suspended in one sliding groove; the tangential system includes a hydraulic cylinder, the piston rod of which is equipped with a motor, the motor is connected to a circular saw, and the top of the cylinder body is equipped with a disc, the diameter of which is larger than the width of the sliding groove, so that the hydraulic cylinder is suspended in another sliding groove; the dust removal system includes a rod, the lower end of which is equipped with a negative pressure suction port, a water mist nozzle, and a dust concentration sensor, and the upper end of which is equipped with a disc, the diameter of which is larger than the width of the sliding groove, so that the rod is magnetically attracted in a third sliding groove; the negative pressure suction port is connected to a negative pressure fan through a pipe; the dust removal system also includes a dust concentration sensor.

[0007] Furthermore, the tangent system also includes a laser rangefinder and a pressure sensor. The laser rangefinder is used to detect the distance from the steel strand to the cutting point of the circular saw, and the pressure sensor is used to detect the pressure generated during the cutting process of the circular saw.

[0008] Furthermore, the vehicle body is equipped with drive wheels at the bottom and a drive system is installed inside the vehicle body to control the drive wheels; it also includes a lithium battery pack that powers the drive system; ultrasonic obstacle avoidance sensors are installed at the four corners of the bottom of the vehicle body and are connected to the drive system; hydraulic leveling outriggers are also installed at the four corners of the vehicle body.

[0009] Furthermore, the first connecting end is a first magnetic quick-release interface, and the second connecting end is a second magnetic quick-release interface.

[0010] Furthermore, a laser scanner is also installed on the vehicle body.

[0011] A method for constructing a tangent and roughening device for precast beams includes the following steps: Step S1, Model Import and Parameter Setting: Import the precast beam BIM model data into the central control system and set the parameters for exposed steel strand length and anchor hole roughening depth. Step S1.1: Scan the work surface before operation with a laser scanner, establish a three-dimensional cloud model, compare the actual position of the steel strand with the coordinates of the three-dimensional cloud model, and move the vehicle to the work surface position. Step S2, Cutting Operation: The robotic arm is equipped with a cutting system. After the hydraulic clamp holds the steel strand, the robotic arm controls the cutting mechanism to cut along the axial direction of the steel strand. Step S3, Chipping Operation: The robotic arm switches to the chipping system to remove concrete dust from the anchor hole; Step S3.1: Scan the working surface after the operation with a laser scanner to obtain the roughness data of the chiseled surface in the anchor hole, calculate the effective chiseled area ratio, and automatically rework areas that do not meet the standards. Step S4: Start the dust removal system to remove dust.

[0012] Furthermore, in step S2, the initial cutting speed is set to 20 mm / s, and when the cutting depth reaches 80% of the diameter of the steel strand, the cutting speed is adjusted to 5 mm / s.

[0013] Furthermore, in step S3, the amplitude of the impact drill bit in the burring system is controlled at 0.1-0.3 mm.

[0014] Furthermore, in step S4, the dust removal mode is switched according to the reading of the dust concentration sensor. When PM10 > 5 mg / m³, water mist dust suppression is activated, and when PM10 ≤ 5 mg / m³, only negative pressure dust collection is operated.

[0015] Compared with the prior art, the present invention has the following advantages and beneficial effects: 1. This invention has four main structures installed on the vehicle body: a tangent system, a chiseling system, a dust removal system, and a robotic arm. The tangent system, chiseling system, and dust removal system are used for cutting steel strands, chiseling anchor holes, and removing dust from the working surface, respectively. The robotic arm is used to switch between the tangent system, chiseling system, and dust removal system. The switching process is relatively fast, which can improve efficiency. Moreover, the robotic arm controls the tangent system and chiseling system to cut steel strands and chisel anchor holes. Compared with manual operation, the construction efficiency is higher and it is safer.

[0016] 2. The tangent system also includes a laser rangefinder and a pressure sensor. The laser rangefinder is used to detect the distance from the steel strand to the cutting point of the circular saw, so that the alignment between cuts can be more accurate. The pressure sensor is used to detect the pressure generated during the cutting of the circular saw.

[0017] 3. The dust removal system is equipped with a negative pressure dust suction port, a water mist nozzle, and a dust concentration sensor, thus having two dust removal modes: water mist dust suppression and negative pressure dust suction, which can be used to treat dust of different concentrations. Attached Figure Description

[0018] Figure 1 This is a flowchart of the present invention.

[0019] Figure 2 This is a structural diagram of the device of the present invention.

[0020] The labels in the diagram are as follows: 1-vehicle body, 2-robotic arm, 3-scraping system, 4-tangential system, 5-dust removal system, 6-lithium battery pack. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, so as to provide a better understanding of the concept of the present invention, the technical problem solved, the technical features constituting the technical solution, and the technical effects brought about.

[0022] like Figure 2 As shown, a tangent and chiseling device for a precast beam includes a vehicle body 1; a robotic arm 2 is mounted on the vehicle body 1, and the robotic arm 2 is provided with a first connecting end; a chiseling system 3, a tangent system 4, and a dust removal system 5 are each provided with a second connecting end; the second connecting ends of the chiseling system 3, the tangent system 4, and the dust removal system 5 are switchably connected to the first connecting end; a central control system is installed inside the vehicle body 1, and the central control system is connected to the robotic arm 2; the central control system is also connected to the chiseling system 3, the tangent system 4, or the dust removal system connected to the first connecting end.

[0023] This invention features four main structures mounted on the vehicle body 1: a tangent system 4, a chiseling system 3, a dust removal system 5, and a robotic arm 2. The tangent system 4, chiseling system 3, and dust removal system 5 are used for cutting steel strands, chiseling anchor holes, and removing dust from the work surface, respectively. The robotic arm 2 switches between these systems. It moves the tangent system 4 to the work surface for cutting, then moves the chiseling system 3 to the work surface for chiseling, and finally moves the dust removal system 5 to the work surface for dust removal. Using the robotic arm 2 to switch between these systems allows for rapid switching, improving efficiency. Furthermore, the robotic arm 2's control of the tangent system 4 and chiseling system 3 for steel strand cutting and anchor hole chiseling results in higher construction efficiency and greater safety compared to manual labor.

[0024] Furthermore, the vehicle body 1 is equipped with a bracket, and the top of the bracket is provided with three sliding grooves; the chiseling system 3 includes a telescopic mechanical arm 2, the bottom of which is connected to an impact drill bit, and the top of the telescopic mechanical arm 2 is provided with a disc, the diameter of which is larger than the width of the sliding groove, so that the telescopic mechanical arm 2 is suspended in one sliding groove; the tangential system 4 includes a hydraulic cylinder, the piston rod of which is equipped with a motor, the motor is connected to a circular saw, and the top of the cylinder body of the hydraulic cylinder is provided with a disc, the diameter of which is larger than the width of the sliding groove, so that the hydraulic cylinder is suspended in another sliding groove; the dust removal system 5 includes a rod, the lower end of which is provided with a negative pressure dust suction port, a water mist nozzle, and a dust concentration sensor, and the upper end of which is provided with a disc, the diameter of which is larger than the width of the sliding groove, so that the rod is magnetically attracted in a third sliding groove; the negative pressure dust suction port is connected to a negative pressure fan through a pipe; the dust removal system 5 also includes a dust concentration sensor. The present invention installs a bracket on the vehicle body 1, and the bracket is provided with three sliding grooves. The three sliding grooves are respectively used to suspend and place the tangent system 4, the chisel system 3 and the dust removal system 5, so as to facilitate the robotic arm 2 to switch and install the tangent system 4, the chisel system 3 and the dust removal system 5.

[0025] Furthermore, the tangent system 4 also includes a laser rangefinder and a pressure sensor. The laser rangefinder is used to detect the distance from the steel strand to the cutting point of the circular saw, so that the alignment between cuts can be more accurate. The pressure sensor is used to detect the pressure generated during the cutting of the circular saw.

[0026] Furthermore, the vehicle body 1 is equipped with drive wheels at its bottom, and a drive system is installed inside the vehicle body 1 to control the drive wheels; it also includes a lithium battery pack 6, which powers the drive system; ultrasonic obstacle avoidance sensors are installed at the four corners of the bottom of the vehicle body 1, and these sensors are connected to the drive system; hydraulic leveling outriggers are also installed at the four corners of the vehicle body 1. When the vehicle body 1 is stopped for operation, the hydraulic leveling outriggers are used to support the vehicle body 1 and adjust its overall levelness to facilitate subsequent construction.

[0027] Furthermore, the first connecting end is a first magnetic quick-release interface, and the second connecting end is a second magnetic quick-release interface. The principle of the magnetic quick-release is based on the adsorption principle of opposite magnetic poles of neodymium iron boron magnets, achieving a stable connection through a multi-magnetic point array. Its core lies in utilizing the strong magnetic field generated by rare-earth permanent magnet materials (such as N42-N52 grade neodymium iron boron), achieving rapid adsorption and separation of components through magnetic pole interaction. An anti-accidental contact safety lock is installed at both the first and second magnetic quick-release interfaces as a second layer of safety. An electromagnet is used to connect the first and second connecting ends. An armature is installed on the second connecting end, and an electromagnet is installed on the first connecting end. Energizing the electromagnet causes it to become magnetic, thus completing the connection between the first and second connecting ends. Disconnection is achieved by de-energizing the electromagnet.

[0028] Furthermore, a laser scanner is also installed on the vehicle body 1. The laser scanner can scan the working surface and create a model, which is used to compare with the model pre-input into the central control system, facilitating the construction of the robotic arm 2.

[0029] The robotic arm 2 in this invention is a prior art robotic arm 2 with high-precision sensors. Preferably, the robotic arm 2 is the Eft robot robotic arm 2.

[0030] like Figure 1 As shown, a construction method for a tangent and roughening device for precast beams includes the following steps: Step S1, Model Import and Parameter Setting: Import the precast beam BIM model data into the central control system and set the parameters for exposed steel strand length and anchor hole roughening depth. Step S1.1: Scan the work surface before operation with a laser scanner, establish a three-dimensional cloud model, compare the actual position of the steel strand with the coordinates of the three-dimensional cloud model, and move vehicle 1 to the work surface position. Step S2, Cutting operation: The robotic arm 2 is equipped with the wire cutting system 4. After the hydraulic clamp holds the steel strand, the robotic arm 2 controls the cutting mechanism to cut along the axial direction of the steel strand. Step S3, Chipping Operation: The robotic arm 2 switches to the chipping system 3 to remove concrete dust from the anchor hole; Step S3.1: Scan the working surface after the operation with a laser scanner to obtain the roughness data of the chiseled surface in the anchor hole, calculate the effective chiseled area ratio, and automatically rework areas that do not meet the standards. Step S4: Start the dust removal system 5 to remove dust.

[0031] Furthermore, in step S2, the initial cutting speed is set to 20 mm / s, and when the cutting depth reaches 80% of the diameter of the steel strand, the cutting speed is adjusted to 5 mm / s.

[0032] Furthermore, in step S3, the amplitude of the impact drill bit in the burring system 3 is controlled at 0.1-0.3 mm.

[0033] Furthermore, in step S4, the dust removal mode is switched according to the reading of the dust concentration sensor. When PM10 > 5 mg / m³, water mist dust suppression is activated, and when PM10 ≤ 5 mg / m³, only negative pressure dust collection is operated.

[0034] The specific construction steps are as follows: Before step S1, construction preparation must be carried out. Operators need to undergo three levels of technical and safety technical briefings to familiarize themselves with the safety and quality requirements of the construction process. At the same time, they also need to receive equipment operation training to familiarize themselves with the parameter adjustment and operating principles of the equipment during the construction process.

[0035] The steel strand cutting and anchor hole roughening construction of this invention needs to be carried out after the prestressing tension of the precast beam is completed. After the previous construction process is completed, the vehicle body 1 is moved to a position 1m from the end of the precast beam to prepare for steel strand cutting and anchor hole roughening construction.

[0036] Step S1, Model Import and Parameter Setting: Import the precast beam BIM model data into the central control system, input the relevant parameters to be constructed, and set the operation procedures, including but not limited to installing the steel strand cut-off head, aligning the cut-off head, steel strand cutting construction, storing the cut-off head, installing the roughening probe, aligning the roughening probe, roughening the anchor hole, storing the probe, etc., to prepare for the next step of construction.

[0037] Step S1.1: Scan the work surface before operation with a laser scanner to establish a three-dimensional cloud model. Compare the actual position of the steel strand with the coordinates of the three-dimensional cloud model to complete the positioning of the work surface. Move vehicle 1 to the work surface position.

[0038] Step S2: First, ensure that all structures of the device are in good working order. Check the operation of robotic arm 2 to ensure that all components of robotic arm 2 are normal and well lubricated. Start robotic arm 2 through the human-machine interface of the central control system. Set the movement trajectory of robotic arm 2 according to the preset program. Based on the coordinate values ​​set by the system program, robotic arm 2 will automatically move to the support and perform precise grasping to complete the installation of the tangent system 4. During the operation, the operator closely monitors the robot's movements to ensure that its movements are smooth and without abnormalities.

[0039] After the cutting system 4 is installed, the circular saw and the steel strand are aligned on the human-machine interface of the central control system. The robotic arm 2 moves to the steel strand bundle to be cut and stops when it is about 10cm away from the steel strand bundle, thus completing the initial alignment of the cutting head.

[0040] The human-machine interface of the central control system selects the steel strand bundle to be cut and initiates the cutting program. Upon receiving the instruction, robotic arm 2 uses high-precision sensors and the control system to cut the steel strands. Once one bundle of steel strands is cut, robotic arm 2 automatically moves to the position of the next bundle and repeats the cutting process until all steel strands on the end face of the precast beam have been cut. Throughout the process, the motion trajectory of robotic arm 2 is pre-programmed and calibrated to ensure consistent accuracy and efficiency in each cut.

[0041] After the steel strands are cut, the exposed length needs to be accurately measured to ensure it meets the requirements of the engineering design and construction specifications. The exposed length is measured using a steel ruler. If the measurement shows that the exposed length meets the specifications, it indicates that the section of steel strand has met the expected technical indicators and can proceed smoothly to the next stage of construction. If the measurement shows that the exposed length does not meet the specifications, corrective measures are taken, the cutting operation is repeated, and the measurement is repeated until the exposed length of all steel strands meets the specified standard.

[0042] Step S3: The robotic arm 2 switches to install the chiseling system 3, and completes the storage of the tangent system 4 on the human-machine interface of the central control system, storing it back on the support. After storing the tangent system 4, the robotic arm 2 is moved to the chiseling system 3 on the support, and the installation is completed after precise alignment with the chiseling system 3.

[0043] After the chiseling system 3 is installed, the alignment of the chiseling system 3 with the anchor hole is completed on the human-machine interface of the central control system. The robotic arm 2 moves to the anchor hole to be chiseled and stops when it is about 10cm away from the end of the anchor hole, thus completing the initial alignment of the chiseling system 3.

[0044] After the initial alignment of the chiseling system 3 is completed, the chiseling head is precisely aligned with the anchor hole through the coordinate fine-tuning in the operating system via the human-machine interface of the central control system. After confirming that the position is correct, the anchor hole is ready for chiseling.

[0045] After the roughening system 3 is aligned, the robotic arm 2 is activated to roughen the surface of the anchor hole evenly and forcefully. Once one anchor hole is roughened, it is quickly aligned with the next hole to begin the next cycle of construction.

[0046] Step S3.1: After the roughening process of the anchor cavity is completed, the quality of the roughening is inspected. The inspection includes, but is not limited to, the roughening depth and quality. The roughened area must not be less than 71%. Only after passing the inspection can the next process be carried out. If it fails, the work is repeated until the roughening quality is satisfactory, ensuring that the surface roughness is suitable for subsequent anchor sealing requirements and does not affect the overall structural strength of the anchor cavity. The inspection process involves scanning the work surface after the operation with a laser scanner to obtain the roughness data of the roughened surface within the anchor cavity, and calculating the effective roughened area percentage for judgment.

[0047] After completing the roughening of the anchor holes and the quality inspection of the roughening, the robotic arm 2 is controlled via the human-machine interface of the central control system to return the roughening system 3 to the support. Dust removal is then performed on the work surface, switching the dust removal mode based on the dust concentration sensor readings. When PM10 > 5 mg / m³, water mist dust suppression is activated; when PM10 ≤ 5 mg / m³, only negative pressure dust collection is used. Finally, the power to the invention is turned off, the site is cleaned (including the cut steel strands and roughened concrete residue), and the invention moves to the next precast beam requiring construction, completing the construction.

[0048] The terms "connection" and "fixing" appearing in the description of this invention can refer to fixed connection, processing and forming, welding, or mechanical connection. The specific meaning of the above terms in this invention should be understood according to the specific circumstances.

[0049] In the description of this invention, the terms "center," "upper," "lower," "horizontal," "inner," and "outer," etc., are used only to indicate the orientation or positional relationship for the convenience of describing this invention and to simplify the description, and do not indicate or imply a specific orientation that the device or element referred to must have, and therefore should not be construed as a limitation of this invention.

[0050] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A tangent and roughening device for precast beams, characterized in that: Including the vehicle body (1); A robotic arm (2) is installed on the vehicle body (1). The robotic arm (2) is provided with a first connecting end. The burring system (3), the tangent system (4), and the dust removal system (5) are each provided with a second connecting end. The second connecting ends of the burring system (3), the tangent system (4), and the dust removal system (5) can be switched to the first connecting end. The vehicle body (1) is equipped with a central control system, which is connected to the robotic arm (2); the central control system is also connected to a chiseling system (3), a tangent system (4), or a dust removal system (5) connected to the first connection end.

2. The tangent and roughening device for a precast beam according to claim 1, characterized in that: A bracket is installed on the vehicle body (1), and three sliding grooves are provided on the top of the bracket; The chiseling system (3) includes a telescopic mechanical arm (2), with an impact drill bit connected to the bottom of the telescopic mechanical arm, and a disc provided at the top of the telescopic mechanical arm (2). The diameter of the disc is greater than the width of the chute, so that the telescopic mechanical arm (2) is suspended in a chute. The tangent system (4) includes a hydraulic cylinder, the piston rod of which is equipped with a motor, the motor is connected to a circular saw, and a disc is provided on the top of the cylinder body of the hydraulic cylinder. The diameter of the disc is greater than the width of the chute, so that the hydraulic cylinder is suspended in another chute. The dust removal system (5) includes a rod body, with a negative pressure suction port, a water mist nozzle and a dust concentration sensor at the lower end of the rod body, and a disc at the upper end of the rod body. The diameter of the disc is greater than the width of the slide groove, so that the rod body is magnetically attracted in the third slide groove. The negative pressure suction port is connected to a negative pressure fan through a pipe. The dust removal system (5) also includes a dust concentration sensor.

3. The tangent and roughening device for a precast beam according to claim 2, characterized in that: The tangent system (4) also includes a laser rangefinder and a pressure sensor. The laser rangefinder is used to detect the distance from the steel strand to the cutting point of the circular saw, and the pressure sensor is used to detect the pressure generated when the circular saw is cutting.

4. The tangent and roughening device for a precast beam according to claim 1, characterized in that: The vehicle body (1) is equipped with drive wheels at the bottom and a drive system is installed inside the vehicle body (1). The drive system controls the drive wheels. It also includes a lithium battery pack (6) that powers the drive system. Ultrasonic obstacle avoidance sensors are installed at the four corners of the bottom of the vehicle body (1), and the ultrasonic obstacle avoidance sensors are connected to the drive system. Hydraulic leveling outriggers are also installed at the four corners of the vehicle body (1).

5. The tangent and roughening device for a precast beam according to claim 1, characterized in that: The first connecting end is a first magnetic quick-release interface, and the second connecting end is a second magnetic quick-release interface.

6. The tangent and roughening device for a precast beam according to claim 1, characterized in that: A laser scanner is also installed on the vehicle body (1).

7. A construction method for a tangent and roughening device for precast beams based on any one of claims 1-6, characterized in that, Includes the following steps: Step S1, Model Import and Parameter Setting: Import the precast beam BIM model data into the central control system and set the parameters for exposed steel strand length and anchor hole roughening depth. Step S1.1: Scan the work surface before the operation with a laser scanner, establish a three-dimensional cloud model, compare the actual position of the steel strand with the coordinates of the three-dimensional cloud model, and move the vehicle (1) to the work surface position. Step S2, Cutting operation: The robotic arm (2) installs the wire cutting system (4). After the hydraulic clamp holds the steel strand, the robotic arm (2) controls the cutting mechanism to cut along the axial direction of the steel strand. Step S3, Chipping Operation: The robotic arm (2) switches to the chipping system (3) to remove concrete dust from the anchor hole; Step S3.1: Scan the working surface after the operation with a laser scanner to obtain the roughness data of the chiseled surface in the anchor hole, calculate the effective chiseled area ratio, and automatically rework areas that do not meet the standards. Step S4: Start the dust removal system (5) to remove dust.

8. A construction method for a tangent and roughening device for precast beams according to claim 7, characterized in that, In step S2, the initial cutting speed is set to 20 mm / s. When the cutting depth reaches 80% of the diameter of the steel strand, the cutting speed is adjusted to 5 mm / s.

9. A construction method for a tangent and roughening device for precast beams according to claim 7, characterized in that, In step S3, the amplitude of the impact drill bit in the burring system (3) is controlled at 0.1-0.3 mm.

10. A construction method for a tangent and roughening device for precast beams according to claim 7, characterized in that, In step S4, the dust removal mode is switched according to the reading of the dust concentration sensor. When PM10 > 5 mg / m³, water mist dust suppression is activated, and when PM10 ≤ 5 mg / m³, only negative pressure dust collection is operated.

Images