Intelligent vibrating device for highway concrete precast box girder

Abstract

The application discloses an intelligent vibrating device for highway concrete prefabricated box girder, which comprises a cross beam steel support, traveling devices are fixedly installed at both ends of the cross beam steel support, and a driving device is used for moving the whole device; a movable vibrating rod control device is arranged on the cross beam steel support; a reel type winding and unwinding mechanism is used for controlling the lifting of a flexible shaft vibrating rod by the vibrating rod control device; a vibrating rod clamping mechanism is used for controlling the swing of the flexible shaft vibrating rod; in the inserting stage of the flexible shaft vibrating rod, the pay-off speed of the vibrating rod fixed wheel frame is reduced by about 4-5% relative to the auxiliary roller, differential control is formed, the flexible shaft vibrating rod is continuously conveyed forward, and the flexible hose is always kept in a moderate tension state; in the recycling stage of the flexible shaft vibrating rod, the wheel disc connecting rod mainly drives the vibrating rod fixed wheel frame to be wound, the auxiliary roller provides auxiliary guiding and tensioning effects, and stable recycling is realized. The application can adapt to dynamic changes under actual working conditions, considers the quick insertion and stable recycling of the vibrating rod, reduces the control difficulty and improves the reliability.

Description

Technical Field

[0001] This invention relates to precast box girder construction equipment, specifically to an intelligent vibration device for highway precast concrete box girders. Background Technology

[0002] In bridge engineering, precast box girders are a common structural form, and concrete vibration is a crucial step in their construction. Traditionally, the vibration of the box girder web concrete relies primarily on workers using handheld immersion vibrators. These vibrators consist of a rigid vibrating head, a connecting rubber hose, and a drive motor. Workers must hold the hose and manually insert the rigid vibrating head into the gaps in the web's reinforcing mesh, pushing it into the web to vibrate the concrete. After determining the vibration time based on their experience, they pull the vibrator out by pulling the hose. However, this construction method has many problems: workers cannot accurately control whether the immersion vibrator reaches the bottom of the web where vibration is necessary; the vibration time cannot be standardized and quantified; vibration requires a large amount of manpower; the vibration time is greatly affected by the worker's work attitude, operating habits, and personal experience; and the vibration depth is difficult to control accurately.

[0003] Furthermore, in the vibration compaction of box girder concrete, since the concrete is not laid out in one go but usually in layers, secondary vibration is required. However, the traditional single-person, single-vibrator operation method cannot effectively determine and precisely control whether the concrete at the interface between the upper and lower layers is under-vibrated or over-vibrated, which can easily lead to uneven concrete distribution and ultimately affect the quality of the box girder web.

[0004] To address the aforementioned issues, the industry has proposed several intelligent vibration devices. However, existing intelligent vibration devices suffer from the following shortcomings: (1) In intelligent vibration devices, the vibrating rod exhibits significant nonlinear motion characteristics during insertion and retraction. Especially in complex steel reinforcement environments, the vibrating rod is prone to obstruction, leading to difficulties in matching the front and rear linear velocities, which in turn causes problems such as loosening of the flexible shaft, accumulation and entanglement, or excessive tension. Existing technologies mostly employ front-to-back synchronous control, but the simple synchronization of its linear or angular velocities is difficult to adapt to the dynamic changes under actual working conditions, and cannot meet the requirements of rapid insertion and stable retraction of the vibrating rod. The control is difficult and the reliability is low; (2) The reel-type winding and unwinding structure in existing intelligent vibration devices generally suffers from the problem of power attenuation. Summary of the Invention

[0005] Purpose of the invention: The purpose of this invention is to provide an intelligent vibration device for precast concrete box girders for highways, which can adapt to dynamic changes under actual working conditions, meet the requirements of rapid insertion and stable recovery of the vibrating rod, reduce control difficulty and improve reliability.

[0006] Technical Solution: The present invention provides an intelligent vibration device for precast concrete box girders in highways, comprising a crossbeam steel support, with a traveling device fixedly installed at each end of the crossbeam steel support for driving the overall movement of the device; a movable vibrator control device is provided on the crossbeam steel support, the vibrator control device comprising a flexible shaft vibrator, a retraction mechanism, a vibrator support, and a vibrator clamping mechanism; wherein the retraction mechanism and the vibrator clamping mechanism are both mounted on the vibrator support; the flexible shaft vibrator comprises a vibrator head and a flexible hose, wherein the flexible hose of the flexible shaft vibrator is wound with... The head of the flexible shaft vibrator, wound around the take-up and release mechanism, is held by a vibrator clamping mechanism to suppress the swaying of the vibrator head. The take-up and release mechanism includes a vibrator fixing wheel frame, a second servo motor, a wheel connecting rod, an auxiliary control wheel rod, a transmission belt, and a large pulley. The auxiliary control wheel rod and the second servo motor are mounted on the vibrator support. The auxiliary control wheel rod includes a rotating shaft, and a small pulley and auxiliary roller mounted on the rotating shaft. The wheel connecting rod is connected to the second servo motor via a reduction mechanism. A vibratory rod fixing wheel frame is fitted at each end of the wheel connecting rod. A large pulley is mounted on the outer side of one of the vibratory rod fixing wheel frames, and the large pulley is fitted onto the wheel connecting rod. The large pulley and the small pulley are connected by a transmission belt. The second servo motor simultaneously drives the large pulley and the vibratory rod fixing wheel frame to rotate. When the large pulley rotates, it drives the small pulley to rotate via the transmission belt. The small pulley drives an auxiliary roller to rotate via a rotating shaft. The auxiliary roller is located at the front end of the guide path of the flexible shaft vibratory rod and is used to clamp and control the flexible shaft vibratory rod. The lowering motion is controlled to form a front-to-back graded drive system for the release and retrieval of the flexible shaft vibrator. During the insertion stage of the flexible shaft vibrator, the auxiliary roller acts as the active drive unit for the flexible shaft vibrator. The release speed of the vibrator fixing wheel frame is reduced by about 4-5% relative to the auxiliary roller, forming differential speed control. This allows the flexible shaft vibrator to be continuously conveyed forward while keeping the flexible hose in the flexible shaft vibrator under appropriate tension. During the retrieval stage of the flexible shaft vibrator, the wheel connecting rod drives the vibrator fixing wheel frame to rewind, while the auxiliary roller provides auxiliary guidance and tension, thereby achieving smooth retrieval.

[0007] Furthermore, the flexible hose of the flexible shaft vibrator includes an outer protective rubber tube, a steel wire reinforcement layer, an inner lining tube, and a transmission flexible shaft arranged coaxially from the outside to the inside, and each part of the flexible hose extends continuously along the axial direction of the flexible shaft vibrator and is tightly fitted to form an integrated flexible transmission structure.

[0008] Furthermore, in cases where the reinforcing steel is sparse, the diameter of the drive shaft of the flexible shaft vibrator is 10mm, and the diameter of the vibrator head is 36mm, while the diameter of the vibrator fixing wheel frame is controlled at 56-60mm; in cases where the reinforcing steel is dense, the diameter of the drive shaft of the flexible shaft vibrator is 8mm, and the diameter of the vibrator head is 32mm, while the diameter of the vibrator fixing wheel frame is 52-56mm.

[0009] Furthermore, the steel wire reinforcement layer adopts a steel wire braiding or spiral winding structure to form a circumferential reinforcement skeleton, which is used to withstand axial tensile force and torsional load, and prevent the transmission flexible shaft from deforming or becoming unstable during retraction and bending; the inner liner tube is used to reduce the frictional resistance during transmission and to guide and support the transmission flexible shaft; the transmission flexible shaft is used to transmit the torque at the drive end to the vibrator head of the flexible shaft vibrator, thereby realizing the vibration energy output.

[0010] Furthermore, an automatic cleaning mechanism for the vibratory rod is provided at the position corresponding to the position of the vibratory rod clamping mechanism on the bottom surface of the vibratory support.

[0011] Furthermore, the automatic cleaning mechanism for the vibratory rod includes a cleaning bracket and an annular brush assembly mounted on the cleaning bracket; a scraping guide plate is provided on the lower part of the cleaning bracket below the annular brush assembly.

[0012] Furthermore, when the flexible shaft vibrator is retracted, the vibrator head passes through the annular brush assembly, which performs a circumferential brushing cleaning of the vibrator head surface. The concrete slurry and adhering materials are scraped off and discharged through the slurry guide plate.

[0013] Furthermore, a power generation device is installed at the end of the crossbeam steel support, and a system control cabinet is set on the outside of the crossbeam steel support; the system control cabinet has a built-in control system, which is electrically connected to the traveling device, the vibrating rod control device, and the power generation device, and controls the traveling device, the vibrating rod control device, and the power generation device through the control system.

[0014] Furthermore, the vibratory rod clamping mechanism includes two clamping rollers and a hydraulic cylinder. The two clamping rollers are fixed on a bracket and together clamp the flexible shaft vibratory rod. The hydraulic cylinder drives the bracket equipped with the clamping rollers to move horizontally through the extension and retraction of the hydraulic rod, thereby controlling the swing of the vibratory rod head of the flexible shaft vibratory rod.

[0015] Furthermore, the crossbeam steel support includes a pair of parallel channel steels, with a mounting seat at the bottom of each end of the channel steel. The mounting seats are connected to the traveling device via an angle steel structure. Each channel steel of the crossbeam steel support has a traveling track at its top, and the vibrator control device has a movable base at its bottom. A roller assembly is installed at each of the four corners of the bottom of the movable base. The vibrator control device is mounted on the traveling track of the crossbeam steel support via the roller assembly, forming a rolling engagement. When the control system issues a lateral movement command, the rotary motor drives the movable roller in the roller assembly to rotate, thereby moving the vibrator control device to cover different vibration points of the box girder.

[0016] Beneficial effects: Compared with the prior art, the significant technical effects of the present invention are as follows:

[0017] (1) Through the synergistic effect of the above structure and differential control method, the tension adaptive adjustment of the vibrating rod during the winding and unwinding process under complex working conditions is realized, ensuring the fit and compactness of the flexible shaft during the entire insertion and extraction process, effectively avoiding the problems of entanglement, knotting and local accumulation, and improving the automatic control accuracy and operational reliability of the reel vibrating device.

[0018] (2) The reasonable size range of the reel wheel of the present invention can reduce the power loss caused by the reel structure, ensure the effective transmission of vibration energy of the vibrator, and improve the concrete vibration efficiency. This structure solves the problem of power attenuation that is common in reel-type winding and unwinding structures.

[0019] (3) The overall structure of the flexible shaft vibrator of the present invention has strong tensile strength and torsional stiffness. It is not easy to deform or become unstable during the winding, stretching and bending process. It can also transmit the torque of the drive end to the vibrator head, thereby realizing the output of vibration energy.

[0020] (4) The automatic cleaning mechanism of the vibrating rod of the present invention can avoid the failure of the sensor due to the adhesion of concrete slurry, improve the long-term reliability of the automated vibration system, and reduce the amount of manual cleaning and maintenance work. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0022] Figure 2 This is a front view of the present invention;

[0023] Figure 3 This is a schematic diagram of the traveling device in this invention;

[0024] Figure 4 This is a schematic diagram of the structure of the vibratory rod control device in this invention;

[0025] Figure 5 This is an exploded view of the components of the vibratory rod control device in this invention;

[0026] Figure 6 This is a schematic diagram of the retraction and extension mechanism in this invention.

[0027] Figure 7 This is a cross-sectional view of the flexible hose of the flexible shaft vibrator in this invention;

[0028] Figure 8 This is a schematic diagram of the automatic cleaning mechanism for the vibrating rod in this invention;

[0029] Figure 9 This is a schematic diagram of the power generation device in this invention;

[0030] Figure 10 This is a flowchart illustrating the operation of the intelligent vibration device for precast concrete box girders for highways as described in this invention. Detailed Implementation

[0031] The technical solution of the present invention will now be described in detail with reference to specific embodiments and accompanying drawings.

[0032] like Figure 1-10 As shown, an intelligent vibration device for precast concrete box girders of highways according to the present invention includes the following components: a crossbeam steel support 1, a tracked moving mechanism 2, a track 21, a servo drive motor set 22, a guide wheel set 23, a vibrator control device 3, a flexible shaft vibrator 31, a take-up and release mechanism 32, a displacement encoder 33, a rotary motor 34, a vibration support 35, a vibrator clamping mechanism 36, a two-dimensional laser scanning system 37, a hydraulic cylinder stroke sensor 38, a vibrator fixing wheel frame 39, a second servo motor 40, a power generation device 4, a diesel generator 41, an inverter 42, an oil tank 43, a circuit control panel 44, a battery 45, a system control cabinet 5, a wheel connecting rod 51, an auxiliary control wheel rod 52, a small pulley 521, an auxiliary roller 522, a rotating shaft 523, a transmission belt 53, a large pulley 54, a vibrator drive motor 55, a clamping roller 56, a hydraulic cylinder 57, a shaft 58, an inclination sensor 59, and a moving roller 60.

[0033] like Figure 1 and Figure 2 As shown, a traveling device is fixedly installed at each end of the crossbeam steel support 1 to drive the overall movement of the device. A movable vibrator control device 3 is mounted on the crossbeam steel support 1. The vibrator control device 3 is driven by an independent rotary motor 34, enabling precise movement along a slide rail to cover different vibration points of the box girder. The rotary motor 34 has a servo driver. A generator 4 is installed at the end of the crossbeam steel support 1, and a system control cabinet 5 is located on the outside of the crossbeam steel support 1. The system control cabinet 5 has a built-in control system, which is electrically connected to the traveling device, the vibrator control device 3, and the generator 4, enabling intelligent control of the entire device.

[0034] The crossbeam steel support 1 serves as the main frame and includes a pair of parallel channel steels. Each end of the channel steel has a mounting base at its bottom, which is connected to the traveling device via an angle steel structure. Each channel steel of the crossbeam steel support 1 has a slide rail at its top. The vibrator control device 3 is driven by a rotary motor 34 and moves left and right along the slide rail (X-axis direction) via a slider to cover different vibration points on the box girder. The design of the crossbeam steel support 1 ensures the stability and strength of the overall structure, and the fixing method using angle steel structures further enhances the safety and reliability of the device.

[0035] like Figure 3 As shown, in this embodiment, the traveling device is a tracked moving mechanism 2, which includes a track 21, a servo drive motor assembly 22, a guide wheel assembly 23, and a travel limit switch. The guide wheel assembly 23 is installed inside the track 21, and the servo drive motor assembly 22 drives the guide wheel assembly 23 to rotate, thereby moving the track 21. The servo drive motor assembly 22 has a servo driver. The track 21 is made of high-strength nylon material to ensure wear resistance and tensile strength. The upper surface of the track has anti-slip textures to adapt to various complex working surfaces at the construction site (such as muddy, slippery, or uneven surfaces), improving the device's passability during movement. Simultaneously, the nylon tracked mechanism can solve the vibration effects accompanying vibratory compaction operations, thereby improving operational stability. The servo drive motor assembly 22 serves as the driving device for the tracked moving mechanism 2, and the control system achieves precise closed-loop control of speed and position. The rated power of the servo drive motor assembly 22 is 750 watts, and the rated speed is 3000 rpm. The servo drive motor assembly 22, in conjunction with the travel limit switch, enables precise stepping movement of the entire machine along the longitudinal direction (Y-axis) of the box girder. The guide wheel assembly 23 employs a bidirectional guiding structure to ensure the tracks remain stable during travel and turning, preventing derailment and improving movement accuracy. A travel limit switch is located at the bottom of the track movement mechanism 2 to prevent excessive track movement that could lead to collisions with obstacles or separation from the working area. The travel limit switch not only enhances the safety of the device but also effectively prevents equipment damage caused by improper operation.

[0036] By employing a tracked precision moving mechanism, the problems of slippery and uneven road surfaces at construction sites, as well as the stability issues during heavy-load equipment movement, can be solved. Track 21 is made of high-strength modified nylon, possessing excellent wear resistance and corrosion resistance, resisting the erosion of concrete slurry, and effectively solving the vibration impact during compaction operations. The outer surface of track 21 is molded with deep grooves, anti-slip herringbone patterns, or transverse serrations, effectively increasing the coefficient of friction with the concrete beam surface, preventing slippage in wet or slurry conditions, and ensuring traction for movement.

[0037] The servo precision drive unit adopts a combined drive structure of a servo motor and a precision reducer. The servo motor is vertically mounted above the reducer, and the reducer increases the output torque to drive the drive wheel to rotate. Servo control realizes closed-loop control of speed and position, providing a foundation for fixed-point vibration compaction.

[0038] The bidirectional guide and support wheel assembly contains a load-bearing wheel assembly to evenly distribute the weight of the entire machine and prevent localized overload deformation of the tracks. Lateral limiting guide structures (bidirectional guide) are provided on both sides to lock the box girder's travel track or edge, preventing lateral deviation or derailment due to severe vibrations during movement and ensuring the stability of straight-line travel.

[0039] like Figure 4 and Figure 5 As shown, the vibratory rod control device 3 is the core for achieving precise vibration, including a flexible shaft vibratory rod 31, a take-up and take-down mechanism 32, a displacement encoder 33, a rotary motor 34, a vibratory support 35, a vibratory rod clamping mechanism 36, a two-dimensional laser scanning system 37, and a hydraulic cylinder stroke sensor 38. The bottom of the vibratory rod control device 3 is equipped with a movable base, and roller assemblies are installed at the four corners of the bottom of the movable base. The movable rollers 60 in the roller assembly are preferably steel rollers with flanges, adapted to the shape of the traveling track to prevent the device from derailing during movement. The vibratory rod control device 3 is mounted on the traveling track of the crossbeam steel support 1 via the movable rollers 60 at the bottom, forming a rolling engagement. When the control system issues a lateral movement command, the rotary motor 34 drives the movable rollers 60 to rotate, thereby moving the vibratory rod control device 3.

[0040] The flexible shaft vibrator 31 includes a vibrator head and a flexible hose. The flexible hose of the flexible shaft vibrator 31 is wound around the retraction mechanism 32, and the vibrator head of the flexible shaft vibrator 31 is clamped by the vibrator clamping mechanism 36, which is used to suppress the swing of the vibrator head of the flexible shaft vibrator 31. In this embodiment, the vibrator head of the flexible shaft vibrator 31 is made of high-strength alloy steel, and the flexible hose with a diameter of 32 mm and a length of 600 mm is wound around the vibrator fixing wheel frame 39. The surface of the flexible hose of the flexible shaft vibrator 31 is provided with anti-slip texture to enhance the vibration effect.

[0041] like Figure 7As shown, the flexible hose of the flexible shaft vibrator 31 includes an outer protective rubber tube 64, a steel wire reinforcement layer 65, an inner lining tube 66, and a transmission flexible shaft 67 arranged coaxially from the outside to the inside. Each part of the flexible hose extends continuously along the axial direction of the flexible shaft vibrator 31 and is tightly fitted to form an integrated flexible transmission structure. Specifically, the outer protective rubber tube 64 is located on the outermost layer and is used to provide a sealed protection for the internal structure, preventing the intrusion of concrete slurry, moisture and impurities, while also possessing wear resistance and impact resistance. The steel wire reinforcement layer 65 is placed between the outer protective rubber tube 64 and the inner liner tube 66, and adopts a steel wire braided or spiral winding structure to form a circumferential reinforcement skeleton, which is used to bear axial tensile force and torsional load, improve the tensile strength and torsional stiffness of the overall structure, and prevent the transmission flexible shaft 67 from deforming or becoming unstable during retraction and bending. The inner liner tube 66 is set inside the steel wire reinforcement layer 65, and its inner wall cooperates with the transmission flexible shaft 67 to reduce the frictional resistance during transmission and to guide and support the transmission flexible shaft 67. The transmission flexible shaft 67 is located in the center position and is used to transmit the torque of the drive end to the vibrator head of the flexible shaft vibrator 31, thereby realizing the vibration energy output.

[0042] In cases of sparse reinforcement, when the diameter of the drive shaft 67 of the flexible shaft vibrator 31 is 10-12mm and the diameter of the vibrator head is 36-38mm, the diameter of the vibrator fixing wheel frame 39 is controlled at 56-60mm. In cases of dense reinforcement, when the diameter of the drive shaft 67 of the flexible shaft vibrator 31 is 6-8mm and the diameter of the vibrator head is 30-32mm, the diameter of the vibrator fixing wheel frame 39 is 52-56mm. Details are as follows:

[0043] This invention proposes a specialized design method to ensure the output power of the vibratory rod while optimizing the size of the winding reel. Specifically, this invention determines a reasonable size range for the winding reel through experiments and dynamic analysis, ensuring its diameter meets the following conditions: minimizing power transmission loss while ensuring smooth winding of the flexible shaft vibratory rod. The diameter of the vibratory rod fixing reel frame 39 is specifically designed for power matching, enabling the flexible shaft vibratory rod 31 to maintain high power transmission efficiency during winding and unwinding.

[0044] Based on the structural parameters of the vibratory rod and its transmission flexible shaft under different working conditions, this invention performs a special design to match the dimensions of the vibratory rod fixing wheel frame 39. The power transmission efficiency is the ratio of the actual output power of the flexible shaft vibratory rod 31 in the coiled state to its output power in the ideal straight state, which is used to characterize the influence of the structure of the vibratory rod fixing wheel frame 39 on the vibration energy transmission performance.

[0045] In the case of sparse reinforcement, a vibrator head with a diameter of 36mm is used, and the corresponding transmission flexible shaft 67 has a diameter of 10mm. The power transmission efficiency corresponding to different diameters of the vibrator fixing wheel frame 39 is shown in the table:

[0046]

[0047] In reinforced concrete applications, a 32mm diameter vibrator is used, with a corresponding 8mm diameter drive shaft. The power transmission efficiency for different reel diameters is shown in the table below.

[0048]

[0049] The diameter of the vibratory rod fixing wheel frame 39 is set to be no less than a preset minimum threshold to ensure that the output power of the flexible shaft vibratory rod 31 in the coiled state is not less than 80% of its output power in the straight state. Simultaneously, the size of the vibratory rod fixing wheel frame 39 is constrained to an upper limit based on the overall structural layout of the device, thus achieving a balance between power transmission efficiency and equipment compactness. Experiments show that when the transmission flexible shaft diameter is 10mm and the vibratory rod head diameter is 36mm, the diameter of the vibratory rod fixing wheel frame 39 is controlled at 56-60mm; when the transmission flexible shaft diameter is 8mm and the vibratory rod head diameter is 32mm, the diameter of the vibratory rod fixing wheel frame 39 is 52-56mm.

[0050] This special design can reduce the power loss caused by the structure of the vibratory rod fixing wheel frame 39, ensure the effective transmission of vibration energy of the vibrator, and improve the efficiency of concrete vibration. This structure solves the power attenuation problem that is common in reel-type winding and unwinding structures.

[0051] The winding and unwinding mechanism 32 and the vibratory rod clamping mechanism 36 are both mounted on the vibratory support 35. The vibratory rod control device 3 uses a reel-type winding and unwinding mechanism 32 to control the raising and lowering of the flexible shaft vibratory rod 31, and controls the swinging of the flexible shaft vibratory rod 31 through the vibratory rod clamping mechanism 36. The specific implementation method is as follows:

[0052] like Figure 6As shown, the retraction mechanism 32 adopts a dual-wheel differential speed control structure. Driven by a second servo motor 40, the retraction mechanism 32 rotates, automatically releasing or retracting the flexible hose portion of the flexible shaft vibrator 31. The second servo motor 40 has a servo driver. In this embodiment, the specific structure of the retraction mechanism 32 is as follows: The retraction mechanism 32 includes a vibrator fixing wheel frame 39, a second servo motor 40, a wheel connecting rod 51, an auxiliary control wheel rod 52, a transmission belt 53, and a large pulley 54. The auxiliary control wheel rod 52 and the second servo motor 40 are mounted on the vibrator support 35. The auxiliary control wheel rod 52 includes a small pulley 521, an auxiliary roller 522, and a rotating shaft 523. The small pulley 521 and the auxiliary roller 522 are mounted on the rotating shaft 523. The wheel connecting rod 51 is connected to the second servo motor 40 via a reduction mechanism. A vibratory rod fixing wheel frame 39 is fitted at each end of the wheel connecting rod 51. A large pulley 54 is mounted on the outer side of the left vibratory rod fixing wheel frame 39, and is fitted onto the wheel connecting rod 51. The large pulley 54 and the small pulley 521 are connected via a transmission belt 53. The second servo motor 40 simultaneously drives the large pulley 54 and the vibratory rod fixing wheel frame 39 to rotate. When the large pulley 54 rotates, it drives the small pulley 521 on the auxiliary control wheel rod 52 to rotate via the transmission belt 53. The small pulley 521 drives the auxiliary roller 522 to rotate via the rotating shaft 523. The second servo motor 40 drives the vibratory rod fixing wheel frame 39 to realize the retrieval of the flexible shaft vibratory rod 31. The two auxiliary rollers 522 on the auxiliary control wheel 52 have the function of assisting in the retrieval and release of the flexible shaft vibratory rod 31. The specific implementation method is as follows: the auxiliary rollers 522 are set at the front end of the guide path of the flexible shaft vibratory rod 31 to clamp the flexible shaft vibratory rod 31 and control its lowering movement, thereby forming a retrieval and release system driven by front and rear stages.

[0053] In terms of control method, the drive motor of the large pulley is reduced in speed by the reduction mechanism to form the recovery side line speed, which is set to a ratio of 1:10 to the release speed of the vibrator rod, so as to realize the "fast insertion and slow withdrawal" control strategy. During the insertion stage of the flexible shaft vibrator rod 31, the auxiliary roller 522 acts as the active drive unit of the flexible shaft vibrator rod 31. When the vibrator rod extends, the reduction mechanism reduces the speed of the vibrator rod fixing wheel frame 39. The release speed of the vibrator rod fixing wheel frame 39 is reduced by about 4-5% relative to the auxiliary roller 522, forming differential speed control, so that the flexible shaft vibrator rod 31... The vibratory rod is continuously fed forward while maintaining a moderate tension in the flexible hose within the flexible shaft vibratory rod 31. In this embodiment, during the insertion phase, the auxiliary roller 522 acts as the active drive unit for the vibratory rod, with a linear speed slightly higher than the unwinding speed of the reel. The linear speed of the auxiliary roller 522 is 21-22 cm / s, while the linear speed of the reel is 20-21 cm / s, ensuring continuous forward feeding of the vibratory rod. Simultaneously, the unwinding speed of the reel at the rear end is reduced by approximately 4-5% relative to the auxiliary roller 522, thus maintaining a moderate tension in the flexible shaft and preventing slackness or tangling. During the retrieval phase of the flexible shaft vibratory rod 31, the wheel connecting rod 51 drives the vibratory rod to be wound up on the fixed wheel frame 39, with the auxiliary roller 522 providing auxiliary guidance and tensioning, thereby achieving smooth retrieval.

[0054] It should be noted that the wheel connecting rod 51 is connected to the reduction mechanism. When the vibrator is inserted, the reduction mechanism slows down the vibrator fixing wheel frame 39. When the vibrator is retracted, the reduction mechanism does not work.

[0055] Through the synergistic effect of the above structure and differential speed control method, the tension of the vibrator rod is adaptively adjusted during the winding and unwinding process under complex working conditions, ensuring the fit and compactness of the flexible shaft throughout the insertion and extraction process, effectively avoiding problems such as tangling, knotting and local accumulation, and improving the automation control accuracy and operational reliability of the reel-type vibrator.

[0056] The vibratory rod fixing wheel frame 39 and auxiliary rollers work together to automatically release (lowering insertion) and retract (rising withdrawal) the flexible shaft vibratory rod 31 wound on the vibratory rod fixing wheel frame 39. In this embodiment, the rated power of the second servo motor 40 is 750 watts, the rated speed is 3000 rpm, and the second servo motor 40 is set with a current / torque threshold (equivalent to a 15 kg resistance limit) to prevent over-insertion. When the flexible shaft vibratory rod 31 encounters resistance greater than 15 kg, the release and retraction mechanism automatically stops working. When the flexible shaft vibratory rod 31 is lowered, if the head of the vibratory rod touches an unscanned horizontal steel bar or foreign object, the load on the second servo motor 40 increases instantaneously. After the control system detects that the torque exceeds the limit, it will immediately instruct the second servo motor 40 to stop releasing the rod and slightly reverse to retract it. Then, it will control the tilt adjustment motor to fine-tune the angle and try to lower it again.

[0057] The vibratory rod clamping mechanism 36 includes two clamping rollers 56 and a hydraulic cylinder 57. The two clamping rollers 56 are fixed on a bracket and together clamp the flexible shaft vibratory rod 31. The hydraulic cylinder 57 drives the bracket equipped with the clamping rollers 56 to move horizontally through the extension and retraction of the hydraulic rod, thereby controlling the swing of the vibratory rod head of the flexible shaft vibratory rod 31. The swing angle range is [insert range here]. arrive .

[0058] A two-dimensional laser scanning system 37 is installed at the front end of the vibratory support 35 for real-time scanning and positioning of the reinforcing bar cage. The two-dimensional laser scanning system 37 consists of a laser and a receiver, controlled by a control system. It scans the reinforcing bar cage in real time, acquiring the position and distribution data of the reinforcing bars, and achieving real-time scanning and positioning of the reinforcing bar cage through the control system. The scanned data is displayed in real time on a screen, allowing workers to adjust the position of the vibratory rod according to the displayed information, achieving precise vibration. The two-dimensional laser scanning system 37 performs real-time scanning and 3D modeling of the reinforcing bar cage in front of the vibratory rod, accurately positioning the reinforcing bars. The application of the two-dimensional laser scanning system 37 significantly improves the efficiency and accuracy of the vibration process, reducing errors caused by manual measurement.

[0059] The hydraulic cylinder stroke sensor 38 is mounted on a shaft 58 next to the vibratory rod fixing wheel frame 39. The shaft 58 is mounted on the vibratory support 35. The hydraulic cylinder stroke sensor 38 is used to detect the extension and retraction distance of the flexible shaft vibratory rod 31 in the vibratory rod fixing wheel frame 39. The control system accurately records the insertion depth of the vibratory rod head of the flexible shaft vibratory rod 31 based on the extension and retraction distance of the flexible shaft vibratory rod 31, and compares it with the preset depth to avoid over-insertion and damage. The insertion depth of the vibratory rod is determined by the length of the flexible shaft vibratory rod 31's flexible hose extension. When the insertion depth reaches the preset value, the control system automatically stops the insertion of the vibratory rod head, achieving precise vibration. The high-precision resolution of the hydraulic cylinder stroke sensor 38 ensures the accuracy of the vibratory rod head insertion process and reduces uneven vibration caused by human error.

[0060] A displacement encoder 33 and an inclination sensor 59 are installed inside the vibratory rod clamping mechanism 36. The displacement encoder 33 is used to monitor the insertion position of the vibratory rod head in the flexible shaft vibratory rod 31 in real time. In this embodiment, the displacement encoder 33 adopts a high-precision magnetic grating ruler with a resolution of 1 micrometer. The high precision resolution of the displacement encoder 33 ensures the accuracy of the vibratory rod insertion process and reduces uneven vibration caused by human operation errors. The inclination sensor 59 monitors the tilt angle of the vibratory rod head in the flexible shaft vibratory rod 31. The inclination sensor 59 is used to provide real-time feedback on the current angle of the vibratory rod head. The control system compares this data with a preset web angle (e.g., 15°) and drives the hydraulic cylinder to move the vibratory rod clamping mechanism 36, thereby guiding the flexible shaft vibratory rod to slide into the web in the correct posture and avoiding direct impact on the web reinforcement mesh.

[0061] The control system built into system control cabinet 5 uses a Siemens series controller as its core, enabling intelligent control of the entire unit. The control system monitors the tilt angle of the vibrator head in real time using an tilt sensor, compares it with a preset angle, and automatically adjusts the insertion path of the vibrator head to ensure that the vibrator head vibrates at the same angle as the box girder web. This intelligent design of the control system not only improves operational convenience but also reduces the need for manual intervention, thereby enhancing overall work efficiency.

[0062] An automatic cleaning mechanism for vibratory rods is installed on the bottom surface of the vibratory rod support 35 at a position corresponding to the vibratory rod clamping mechanism 36. This automatic cleaning mechanism is also installed along the vibratory rod recovery path. The automatic cleaning mechanism includes a cleaning support 61 and an annular brush assembly 62 mounted on the cleaning support 61; a scraper guide plate 63 is installed on the portion of the cleaning support 61 below the annular brush assembly 62. The annular brush assembly 62 is located inside the vibratory rod recovery channel, with its inner diameter slightly larger than the outer diameter of the vibratory rod head, ensuring that the flexible shaft vibratory rod 31 inevitably passes through the brush area during recovery.

[0063] When the flexible shaft vibrator 31 is retracted, its head passes through the annular brush assembly 62. The annular brush assembly 62 performs a circumferential brushing clean on the surface of the vibrator head, scraping off concrete slurry and adhering materials, which are then discharged through the slurry guide plate 63. This cleaning structure can: automatically remove residual concrete from the surface of the vibrator head, prevent slurry from solidifying and causing sensor contamination, and ensure that the displacement encoder, tilt sensor, and other detection systems are in a stable working state for a long time.

[0064] Compared with the prior art, the present invention has the following advantages: avoiding sensor failure caused by concrete slurry adhesion, improving the long-term operational reliability of the automated vibration system, and reducing the amount of manual cleaning and maintenance work.

[0065] like Figure 9As shown, the power generation unit 4 includes a diesel generator 41, an inverter 42, a fuel tank 43, a circuit control panel 44, and a battery 45. The fuel tank 43 is fixedly mounted on one side of the frame and connected to the fuel inlet of the diesel generator 41 via a fuel pipeline, continuously supplying fuel to the diesel generator 41. The diesel generator 41 serves as the main power source, and its AC output terminal is electrically connected to the input terminal of the circuit control panel 44 via a high-voltage cable. The output terminals of the circuit control panel 44 are electrically connected to the inverter 42 and the battery 45, respectively. The inverter 42 converts the power supply into high-voltage AC power required for servo drive, and its output terminal is connected to each servo drive in the traveling device and the vibrating rod control device 3. The battery 45 (preferably a large-capacity lithium-ion battery pack) is connected to the DC bus via a bidirectional DC / DC conversion module to store and release electrical energy. The power generation unit 4 outputs a stable 380-volt AC voltage with a total power of 5.5 kilowatts, which can meet the power supply requirements of all servo motors (traveling, sliding, and rotating) and the control system, achieving self-sufficiency in power supply. Battery 45 provides short-term power to critical equipment such as the control system when the diesel generator is stopped or switched, ensuring no data loss. Diesel generator 41 has a rated power of 20 kW, a rated frequency of 50 Hz, and a rated voltage of 220 volts. Inverter 42 has an output voltage of 380 volts and a total power of 30 kW, sufficient to meet the power supply needs of all motors.

[0066] This invention achieves precise digital control of the entire vibration process through multi-sensor fusion technology.

[0067] This invention utilizes a two-dimensional laser scanning system to scan and locate the reinforcing steel cage; it employs an inclination sensor to monitor the tilt angle of the vibrator and compares it with a preset angle; the control system automatically adjusts the insertion path, angle, and depth of the vibrator based on the collected data. This invention aims to solve the technical problems of traditional vibration methods, which rely on manual labor and are difficult to precisely control the vibration depth and position, as well as the complex structure, high cost, limited adjustment range, and poor stability of existing automated equipment. This invention improves stability through a tracked movement mechanism; simplifies installation and maintenance through a built-in power generation device; and achieves precise scanning, positioning, and intelligent avoidance of the reinforcing steel cage through a two-dimensional laser scanning system and a torque limiting switch. This invention achieves automated, intelligent, and high-precision control of the vibration process, significantly reducing manpower and improving the construction efficiency and concrete pouring quality of precast box girders. This invention solves the problems of difficult control and low efficiency in traditional vibration methods, as well as the inability of existing equipment to intelligently avoid reinforcing steel and the low degree of automation.

[0068] like Figure 10 As shown, the intelligent vibration device for precast concrete box girders of highways according to the present invention has the following operating method:

[0069] S1. Environmental perception and rebar skeleton modeling based on a two-dimensional laser scanning system: The two-dimensional laser scanning system 37 is used to scan the rebar skeleton in real time, obtain the point cloud data of the surface rebar, and calculate the safe insertion coordinates between the rebar meshes.

[0070] The specific implementation process of step S1 is as follows:

[0071] S1.1 After the traveling device drives the equipment to the designated work position, the control system starts the two-dimensional laser scanning system 37. The laser in the two-dimensional laser scanning system 37 performs high-frequency line scanning on the area to be vibrated below (the opening of the box girder web) to obtain point cloud data of the steel reinforcement surface.

[0072] S1.2 The algorithm module in the control system filters and denoises the point cloud data, removes clutter interference, and identifies the distribution contour of the surface steel bars.

[0073] S1.3 The control system automatically calculates the "safe gap center coordinates" between the steel bars based on the identified steel bar positions and the preset box girder BIM model or parameters, and sets them as the target horizontal coordinates (X-axis) of the flexible shaft vibrator 31. At the same time, it plans the optimal insertion path to avoid the steel bars.

[0074] S1.4 Workers can review the displayed content or manually fine-tune the initial insertion position of the flexible shaft vibrator 31 in semi-automatic mode to achieve more precise vibration.

[0075] The scan data and the generated rebar distribution model in step S1 are displayed in real time on the screen for manual verification or to assist in positioning.

[0076] S2. The control system implements closed-loop angle control, as detailed below:

[0077] S2.1 The control system presets a target tilt angle (e.g., the same angle as the web of the box girder) based on the input box girder design drawings.

[0078] S2.2, Inclination sensor 59 monitors the current tilt angle of the vibrator head in the flexible shaft vibrator 31 in real time.

[0079] S2.3 The control system compares the current tilt angle of the vibrator head in the flexible shaft vibrator 31, which is monitored in real time, with the preset angle of the box girder web. It then performs closed-loop correction through the vibrator clamping mechanism 36 to ensure that the incident angle of the flexible shaft vibrator 31 is consistent with the web inclination angle. The second servo motor 40 of the automatic control retraction mechanism 32 is adjusted to adjust the insertion path of the flexible shaft vibrator 31 to ensure that the flexible shaft vibrator 31 always vibrates at the same angle as the box girder web.

[0080] S3. The control system achieves deep closed-loop control, as detailed below:

[0081] S3.1 The control system presets a target insertion depth according to the construction requirements. After the attitude adjustment is completed, the winch drive motor is started to drive the vibratory rod fixing wheel frame 39 to rotate, and the flexible shaft vibratory rod is released.

[0082] S3.2 The hydraulic cylinder stroke sensor 38 monitors the release length (i.e., insertion depth) of the flexible shaft vibrator 31 in real time.

[0083] S3.3 The control system compares the release length of the flexible shaft vibrator 31 monitored in real time with the preset vibration depth threshold to avoid damage caused by over-insertion.

[0084] S4. The control system performs intelligent decision-making and obstacle avoidance: By integrating data from S1, S2, and S3, the control system dynamically adjusts the horizontal position, incident angle, and lowering speed of the flexible shaft vibrator 31 during insertion; when the preset depth is reached, vibration is automatically activated, and after a preset dwell time, a retrieval action is performed. Details are as follows:

[0085] S4.1 The control system integrates the rebar position data from S1, the angle data from S2, and the depth data from S3 to plan an optimal insertion path.

[0086] S4.2 During insertion along this path, the control system monitors the current or torque value of the second servo motor 40 in real time. If the torque is stable, the flexible shaft vibrator 31 is lowered smoothly. If the laser scanning data in S1 shows that there is a rebar in front, the control system will automatically fine-tune the horizontal position of the vibrator (via the rotary motor 34) or the rotation angle to actively avoid the rebar.

[0087] S4.3 During the lowering process, if the torque is detected to momentarily exceed the preset safety threshold (15 kg resistance), the control system determines that the head of the flexible shaft vibrator 31 has touched the internal concealed reinforcing steel or foreign object. The control system immediately stops the lowering and executes the "reverse-fine-adjust-retry" strategy: instructing the reel to reverse and retract a certain distance (e.g., 50 mm), then controlling the horizontal slide rail motor to fine-tune the horizontal position or controlling the tilt motor to fine-tune the angle, and then attempting to lower the reel again until it bypasses the obstacle.

[0088] Step S4 includes an intelligent torque protection and obstacle avoidance strategy. By monitoring the real-time torque of the second servo motor 40, when the flexible shaft vibrator 31 encounters a resistance value greater than the preset value (corresponding to 15Kgf) during insertion, the control system automatically determines that it has touched the steel bar or that the vibration is complete, and immediately executes the active obstacle avoidance action of "stop lowering - slight retraction - fine adjustment of angle or position - try lowering again" until it bypasses the obstacle or stops vibration and retrieves the vibrator to move to the next point.

[0089] S5. Fixed-point vibration and process control, as detailed below:

[0090] S5.1 When the value of the hydraulic cylinder stroke sensor 38 equals the preset target depth (i.e., the bottom of the web), the reel stops rotating. The control system activates the high-frequency motor inside the vibrator to begin vibration. The system has a built-in timer that strictly adheres to the preset vibration time (e.g., 30 seconds) to ensure concrete compaction and prevent over-vibration or under-vibration.

[0091] S5.2 After the vibration time ends (or 5 seconds before the end), the control system instructs the vibrating rod fixed wheel frame 39 to retract the flexible shaft at a low speed (e.g., 1 m / min) to achieve the process of "vibrating and lifting at the same time", which is conducive to the discharge of air bubbles and the closure of pores.

[0092] S5.3 After the flexible shaft is fully retracted into the guide mechanism, turn off the vibrator, control the traveling device to move to the next station, and repeat steps S1 to S5.

[0093] This invention achieves fully automated control of the entire process, from movement, positioning, obstacle avoidance to precise vibration, significantly improving construction quality and efficiency.

Claims

1. An intelligent vibration device for precast concrete box girders in highways, characterized in that: Includes a crossbeam steel support (1), with a traveling device fixedly installed at each end of the crossbeam steel support (1) for driving the overall movement of the device; The crossbeam steel support (1) is equipped with a movable vibrating rod control device (3). The vibratory rod control device (3) includes a flexible shaft vibratory rod (31), a take-up and put-down mechanism (32), a vibratory support (35), and a vibratory rod clamping mechanism (36); wherein the take-up and put-down mechanism (32) and the vibratory rod clamping mechanism (36) are both installed on the vibratory support (35); The flexible shaft vibrator (31) includes a vibrator head and a flexible hose. The hose of the flexible shaft vibrator (31) is wound around the take-up and release mechanism (32). The vibrator head of the flexible shaft vibrator (31) is clamped by the vibrator clamping mechanism (36). The vibrator clamping mechanism (36) is used to suppress the swing of the vibrator head of the flexible shaft vibrator (31). The take-up and take-down mechanism (32) includes a vibratory rod fixing wheel frame (39), a second servo motor (40), a wheel connecting rod (51), an auxiliary control wheel rod (52), a transmission belt (53), and a large pulley (54); wherein, the auxiliary control wheel rod (52) and the second servo motor (40) are mounted on the vibratory support (35), and the auxiliary control wheel rod (52) includes a rotating shaft (523), and a small pulley (521) and an auxiliary roller (522) fitted on the rotating shaft (523). The wheel connecting rod (51) is connected to the second servo motor (40) through a reduction mechanism; a vibrating rod fixing wheel frame (39) is respectively fitted at both ends of the wheel connecting rod (51), and a large pulley (54) is provided on the outside of one of the vibrating rod fixing wheel frames (39), and the large pulley (54) is fitted on the wheel connecting rod (51); the large pulley (54) and the small pulley (521) are connected by a transmission belt (53); The second servo motor (40) simultaneously drives the large pulley (54) and the vibrating rod fixing wheel frame (39) to rotate. When the large pulley (54) rotates, it drives the small pulley (521) to rotate through the transmission belt (53). The small pulley (521) drives the auxiliary roller (522) to rotate through the rotating shaft (523). The auxiliary roller (522) is set at the front end of the guide path of the flexible shaft vibrator (31) to clamp the flexible shaft vibrator (31) and control its lowering movement, thereby forming a front and rear graded drive release system; During the insertion stage of the flexible shaft vibrator (31), the auxiliary roller (522) serves as the active drive unit for the flexible shaft vibrator (31). The wire feeding speed of the vibrator fixing wheel frame (39) is reduced by about 4-5% relative to the auxiliary roller (522), forming differential speed control. This allows the flexible shaft vibrator (31) to be continuously conveyed forward, while keeping the flexible hose in the flexible shaft vibrator (31) under appropriate tension. During the recovery stage of the flexible shaft vibrator (31), the wheel connecting rod (51) drives the vibrator fixing wheel frame (39) to rewind. The auxiliary roller (522) provides auxiliary guidance and tensioning, thereby achieving smooth recovery.

2. The intelligent vibration device for precast concrete box girders for highways according to claim 1, characterized in that: The flexible hose of the flexible shaft vibrator (31) includes an outer protective rubber tube (64), a steel wire reinforcement layer (65), an inner lining tube (66), and a transmission flexible shaft (67) arranged coaxially from the outside to the inside. Each part of the flexible hose extends continuously along the axial direction of the flexible shaft vibrator (31) and is tightly fitted to form an integrated flexible transmission structure.

3. The intelligent vibration device for precast concrete box girders for highways according to claim 2, characterized in that: In the case of sparse reinforcement, when the diameter of the transmission flexible shaft (67) of the flexible shaft vibrator (31) is 10-12mm and the diameter of the vibrator head of the flexible shaft vibrator (31) is 36-38mm, the diameter of the vibrator fixing wheel frame (39) is controlled at 56-60mm. In the case of dense reinforcement, when the diameter of the transmission flexible shaft (67) of the flexible shaft vibrator (31) is 6-8mm, the diameter of the vibrator head of the flexible shaft vibrator (31) is 30-32mm, and the diameter of the reel of the vibrator fixing wheel frame (39) is 52-56mm.

4. The intelligent vibration device for precast concrete box girders for highways according to claim 2, characterized in that: The steel wire reinforcement layer (65) adopts a steel wire braiding or spiral winding structure to form a circumferential reinforcement skeleton, which is used to bear axial tensile force and torsional load, and to prevent the transmission flexible shaft (67) from deforming or becoming unstable during the winding and bending process; The inner lining tube (66) is used to reduce frictional resistance during transmission and to guide and support the transmission flexible shaft (67); the transmission flexible shaft (67) is used to transmit the torque at the drive end to the head of the flexible shaft vibrator (31), thereby realizing vibration energy output.

5. The intelligent vibrating device for precast concrete box girders for highways according to claim 1, characterized in that: An automatic cleaning mechanism for the vibratory rod is provided at the position corresponding to the bottom surface of the vibratory rod holder (36).

6. The intelligent vibration device for precast concrete box girders for highways according to claim 5, characterized in that: The automatic cleaning mechanism for the vibratory rod includes a cleaning bracket (61) and an annular brush assembly (62) mounted on the cleaning bracket (61); a scraper guide plate (63) is provided on the part of the cleaning bracket (61) below the annular brush assembly (62).

7. The intelligent vibrating device for precast concrete box girders for highways according to claim 6, characterized in that: When the flexible shaft vibrator (31) is retracted, the vibrator head of the flexible shaft vibrator (31) passes through the annular brush assembly (62), and the annular brush assembly (62) performs a circumferential brush cleaning of the vibrator head surface of the flexible shaft vibrator (31). The concrete slurry and attachments are scraped off and discharged through the slurry guide plate (63).

8. The intelligent vibration device for precast concrete box girders for highways according to claim 1, characterized in that: A power generation device (4) is installed at the end of the crossbeam steel support (1), and a system control cabinet (5) is set on the outside of the crossbeam steel support (1). The system control cabinet (5) has a built-in control system. The control system is electrically connected to the traveling device, the vibrating rod control device (3), and the power generation device (4). The control system controls the traveling device, the vibrating rod control device (3), and the power generation device (4).

9. The intelligent vibration device for precast concrete box girders for highways according to claim 1, characterized in that: The vibratory rod clamping mechanism (36) includes two clamping rollers (56) and a hydraulic cylinder (57). The two clamping rollers (56) are fixed on a bracket and together clamp the flexible shaft vibratory rod (31). The hydraulic cylinder (57) drives the bracket equipped with the clamping rollers (56) to move horizontally through the extension and retraction of the hydraulic rod, thereby controlling the swing of the vibratory rod head of the flexible shaft vibratory rod (31).

10. The intelligent vibration device for precast concrete box girders for highways according to claim 8, characterized in that: The crossbeam steel support (1) includes a pair of parallel channel steels, each with a mounting seat at the bottom of both ends of the channel steels, and the mounting seats are connected to the traveling device through an angle steel structure; The top of each channel steel of the crossbeam steel support (1) is provided with a walking track, and the bottom of the vibrating rod control device (3) is provided with a movable base. A roller assembly is installed at each of the four corners of the bottom of the movable base. The vibrating rod control device (3) is mounted on the walking track of the crossbeam steel support (1) through the roller assembly to form a rolling fit. When the control system issues a lateral movement command, the rotary motor (34) drives the moving roller (60) in the roller assembly to rotate, thereby driving the vibratory rod control device (3) to move to cover different vibration points of the box girder.

Images