A prefabrication integrated pedestal for a pre-tensioning method prestressed reinforced concrete bridge deck

Abstract

The application relates to the technical field of bridge engineering assembly type prefabricated component construction, and provides a pre-tensioning method prestressed reinforced concrete bridge deck slab prefabrication integrated pedestal which comprises a pedestal plate, a table plate and two groups of pedestal blocks, the two groups of pedestal blocks are symmetrically arranged on the top of the pedestal plate and are arranged in the longitudinal direction of the pedestal plate at intervals, the table plate is arranged between the two groups of pedestal blocks, and pedestal vertical ends are fixedly arranged at the two ends of the pedestal blocks. The application has the following beneficial effects: the pre-tensioning method prestressed tensioning, formwork synchronous adjustment, automatic steel cutting and prestressed steel limiting and guiding four core functions are integrated in the same pedestal system, the whole-process one-stop operation of the bridge deck slab prefabrication from steel tensioning, formwork erection, steel cutting to concrete pouring is realized, the transfer, assembly and disassembly and alignment of multiple devices are not needed, and the prefabrication preparation period of a single bridge deck slab is shortened.

Description

Technical Field

[0001] This invention is an integrated prefabrication platform for prestressed reinforced concrete bridge deck using the pre-tensioning method, belonging to the technical field of prefabricated component construction for bridge engineering. Background Technology

[0002] With the rapid advancement of transportation infrastructure construction in my country, prefabricated bridge technology has become the mainstream technology for highway and municipal bridge construction due to its core advantages such as high industrialization, fast construction speed, low on-site environmental pollution, and controllable component quality. Among them, prestressed reinforced concrete bridge decks using the pre-tensioning method are widely used in the superstructure of prefabricated bridges because of their uniform prestressing, good structural crack resistance, and low later operation and maintenance costs. The precast platform and formwork system are the core tooling for the industrialized prefabrication of pre-tensioned bridge decks, and their structural performance and functional integration directly determine the prefabrication production efficiency, forming quality, and overall production cost of the bridge deck.

[0003] Currently, to overcome the limitations of traditional prestressed concrete technology, the core research and development focus in the industry is on developing new prestressed concrete formwork-base systems. This aims to achieve functional integration of the formwork and base, improving construction efficiency and quality control. Simultaneously, the industry urgently needs to optimize the formwork-base system to reduce fixed construction costs in industrialized production plants, enable the disassembly and recycling of tooling systems to meet the needs of relocation and cyclical operations between projects in different regions, and improve the utilization rate of formwork tooling through continuous production, further reducing the amortization of precast component production costs. Furthermore, existing prestressed concrete systems often employ a separate design of base foundation, ribbed steel supports, bottom formwork, and side formwork, making it difficult to achieve coordinated assurance of the formwork system's stiffness, strength, and stability, and even more difficult to achieve the combined functions of formwork with base load-bearing and prestressing tension self-balancing.

[0004] However, the existing precast platform and template system still has the following insurmountable technical defects:

[0005] The traditional prestressed concrete system suffers from functional separation, low integration, and poor construction efficiency. The prestressed tensioning platform, casting formwork, and rebar cutting tools are all independent, separate structures. The platform only provides basic load-bearing capacity and cannot simultaneously achieve coordinated operations for core processes such as formwork erection and adjustment, prestressing tensioning, and rebar cutting. Multiple transfers, assembly, disassembly, and alignment of tools are required, resulting in cumbersome procedures, long prefabrication cycles, and high labor and equipment costs. This significantly falls short of the industry's research and development goal of "integrated formwork and platform."

[0006] The traditional pre-tensioning method involves large-scale fixed investment, poor reusability, and high overall costs. Tensioning platforms are mostly fixed concrete platforms, requiring large-scale civil construction in the prefabrication plant area. Plant construction involves high fixed investment and cannot be disassembled or relocated. Existing steel platforms are also mostly welded fixed structures, making it difficult to adapt to the prefabrication needs of different bridge deck specifications, and further hindering cross-project cyclical operations. Tooling utilization is low, and the amortization of prefabricated component production costs remains high, failing to meet the industry's core needs for cost reduction and efficiency improvement.

[0007] The low precision of template adjustment makes it difficult to guarantee the molding quality. Existing bridge deck side templates mostly adopt a manual adjustment method with the help of top screws, resulting in poor synchronization of the adjustment of the templates on both sides. This easily leads to quality problems such as out-of-tolerance component dimensions, loose template joints, and grout leakage. Furthermore, the connection rigidity between the split template and the pedestal is insufficient, making it difficult to maintain the stability of the system during prestressing tensioning and concrete pouring. It is impossible to simultaneously meet the requirements of rigidity, strength, and precise adjustment of the template system.

[0008] Insufficient precision in prestressed construction control leads to high safety risks. In traditional pre-tensioning methods, the tensioning system of the platform is separate from the platform body, making it difficult to achieve self-balancing of the tension reaction force and easily causing platform deformation and asynchronous tensioning. Simultaneously, the prestressed steel bars lack corresponding limiting and guiding structures, making them prone to misalignment and bending during tensioning, resulting in deviations between the applied prestress and the design value. Furthermore, exposed steel bars after tensioning are often cut manually by hand, which not only results in poor cutting precision but also poses significant mechanical injury hazards.

[0009] Large space occupation and poor adaptability. The tooling of each process in the traditional prefabrication system is scattered, and the prefabrication operation requires a large factory area, which is difficult to adapt to the production needs of small spaces; moreover, the tooling system has poor adjustability, which cannot quickly adapt to the prefabrication production of bridge decks with different widths, thicknesses and spans, resulting in low changeover efficiency and difficulty in meeting the flexible production needs of multi-specification components. Summary of the Invention

[0010] To address the shortcomings of existing technologies, the purpose of this invention is to provide an integrated precast platform for prestressed reinforced concrete bridge decks using the pre-tensioning method.

[0011] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0012] A precast integrated platform for prestressed reinforced concrete bridge deck using the prestressed concrete method includes a platform plate, a platform panel, and two sets of platform blocks. The two sets of platform blocks are symmetrically arranged on the top of the platform plate and spaced apart along the longitudinal direction of the platform plate. The platform panel is supported between the two sets of platform blocks, and platform vertical ends are fixed at both ends of each platform block.

[0013] Both ends of the vertical ends of the two sets of platforms are connected to fixed crossbeams; a tensioning drive assembly is provided on the side of one set of fixed crossbeams away from the platform, and the telescopic output end of the tensioning drive assembly is connected to a movable crossbeam. A steel bar anchor sleeve assembly is provided on the side of the movable crossbeam away from the fixed crossbeam, and a perforated sleeve adapted to the steel bar anchor sleeve assembly and prestressed steel bar is provided on the fixed crossbeam.

[0014] A cutting mechanism for cutting prestressed steel bars is provided between the vertical ends of two adjacent sets of platforms;

[0015] The top two sides of the table panel are movably provided with several side templates evenly distributed along the longitudinal direction of the table panel. The top of the base block is provided with an adjustment mechanism that is connected to the corresponding side templates on both sides in a one-to-one correspondence. The adjustment mechanism is used to adjust the distance between the side templates that are arranged opposite to each other on both sides of the table panel.

[0016] Preferably, the tensioning drive assembly includes two hydraulic jacks, which are symmetrically arranged about the longitudinal center line of the platform. The cylinders of both hydraulic jacks are fixedly connected to the fixed crossbeam, and the telescopic rods of both hydraulic jacks are fixedly connected to the movable crossbeam.

[0017] Preferably, the adjustment mechanism includes a housing fixed to the top of the pedestal block, a vertically arranged rectangular frame inside the housing, and horizontally arranged sleeves fixed at the four corners of the rectangular frame. A connecting column is slidably connected inside the sleeve, and one end of the connecting column extends to the outside of the housing and is fixedly connected to the side template on the corresponding side.

[0018] Preferably, the housing is further provided with a synchronous drive assembly, which is used to drive the four connecting columns in the same housing to slide synchronously towards or away from each other along the sleeve.

[0019] The synchronous drive assembly includes a rotating shaft one, a rotating shaft two, four sets of movable rods, and four sets of U-shaped rods;

[0020] The first and second rotating shafts are arranged in parallel vertically inside the housing and located in the middle of one side of the rectangular frame. Both ends of the first and second rotating shafts are fixedly sleeved with movable rods, and the movable rods at both ends of the first rotating shaft and the movable rods at both ends of the second rotating shaft are inclined in opposite directions.

[0021] Each of the four sets of movable rods has a U-shaped rod fixedly connected to its end, and the four sets of U-shaped rods are movably inserted into the four sets of sleeves.

[0022] The connecting column has a U-shaped groove at one end away from the side template, and a sliding column is vertically fixed in the U-shaped groove. The sliding column moves through the through hole in the middle of the U-shaped rod.

[0023] Preferably, the sleeve has stroke holes on both sides that communicate with the internal cavity of the sleeve, and the stroke holes are used to avoid the swing stroke of the U-shaped rod; symmetrical bearing seats are rotatably connected to both the first and second rotating shafts; two sets of vertical plates are symmetrically fixed on the side of the rectangular frame facing the first rotating shaft, and the two sets of vertical plates are fixedly connected to the bearing seats one by one; worm gears are fixedly sleeved in the middle of both the first and second rotating shafts, and the two sets of worm gears are meshed with a horizontally arranged worm, which is installed horizontally between the two sets of vertical plates through the bearings.

[0024] Preferably, a bevel gear one is fixed to the end of the worm gear away from the worm wheel, and a bevel gear two is meshed with the top of the bevel gear one. A vertically arranged drive shaft is fixed to the middle of the top of the bevel gear two. The drive shaft is rotatably connected to the rectangular frame through a bearing seat two. A motor one is fixed on the housing, and the output shaft of the motor one is connected to the drive shaft for driving the drive shaft to rotate. The outer wall of the connecting column is in close sliding fit with the inner wall of the sleeve, and the outer wall of the connecting column is provided with a wear-resistant coating.

[0025] Preferably, the cutting mechanism includes a horizontal plate, the two ends of which are fixedly connected to the top of the vertical ends of two adjacent sets of platforms. A hydraulic cylinder is vertically fixed in the middle of the horizontal plate. A U-shaped support is fixed at the bottom of the piston rod of the hydraulic cylinder. The U-shaped support is provided with parallel threaded rods and guide rods. Two sets of moving blocks are symmetrically threaded on the threaded rods. The moving blocks slide with the guide rods. A cutting machine for cutting prestressed steel bars is fixed at the bottom of the moving blocks. A guide column is symmetrically fixed at the top of the U-shaped support with the hydraulic cylinder as the central axis. The guide column is movably inserted through the horizontal plate. A motor is fixed on one side of the U-shaped support. The output shaft of the motor is coaxially fixedly connected to the end of the threaded rod.

[0026] Preferably, an H-shaped steel beam is fixedly connected to the bottom of the vertical ends of two adjacent sets of the platform. The top of the H-shaped steel beam is provided with a long strip-shaped through hole on the side away from the fixed crossbeam. A limit block is vertically movably connected in the long strip-shaped through hole. The top of the limit block is provided with a limit groove that corresponds to the perforated sleeve.

[0027] Preferably, a second hydraulic cylinder is fixed at the bottom center of the limiting block, and the bottom end of the cylinder body of the second hydraulic cylinder is fixedly connected to the inner bottom of the H-shaped steel beam to drive the limiting block to move vertically up and down; guide rods are symmetrically fixed at the inner bottom of the H-shaped steel beam, and the guide rods are movably inserted through the limiting block.

[0028] Preferably, on the side templates located on both sides of the table panel that are far apart from each other, a positioning plate 1 and a positioning plate 2 extending towards the center of the table panel are fixed laterally. The positioning plate 1 and the positioning plate 2 are vertically offset, and an adjusting screw is threaded through the positioning plate 1 and the positioning plate 2.

[0029] The beneficial effects of this invention are:

[0030] Breaking through the limitations of traditional separate tooling, this system integrates four core functions—prestressed prestressing tensioning, synchronous formwork adjustment, automated rebar cutting, and prestressed rebar positioning and guidance—into a single platform system. This enables one-stop operation of the entire bridge deck prefabrication process, from rebar tensioning and formwork erection to rebar cutting and concrete pouring. It eliminates the need for multiple pieces of equipment to be transported, assembled, disassembled, and aligned, shortening the prefabrication preparation cycle for a single bridge deck and significantly reducing labor and equipment input. This completely solves the problems of functional separation and cumbersome procedures in traditional systems.

[0031] Adopting an all-steel structure design, the main components are all connected by high-strength bolts for detachment, eliminating the need for large-scale concrete platform civil construction in the prefabrication plant area, which significantly reduces the construction investment cost of industrialized production plant area; after the project is completed, it can be quickly disassembled, transported and reassembled, realizing cyclical operation between projects in different regions, greatly improving the utilization rate of tooling, significantly reducing the amortization of production costs of prefabricated components, and solving the core pain points of traditional fixed platforms that require large fixed investment and cannot be transferred and reused.

[0032] Synchronous and precise adjustment and a rigid system ensure comprehensive improvement in component forming quality. The template adjustment mechanism of this invention adopts a single motor drive, worm gear dual-shaft synchronous transmission, and linkage structure, which can realize synchronous stepless adjustment of the side templates on both sides of the bridge deck. The adjustment synchronization error is small, which completely solves the problems of poor synchronization and low precision of manual adjustment. At the same time, the template and the main body of the platform are rigidly connected to form an integral force-bearing system with sufficient rigidity, strength and stability. It can effectively resist the tension reaction force and the lateral pressure of concrete pouring. Combined with the template joint fine adjustment structure, it eliminates quality defects such as dimensional deviation and grout leakage, ensuring the forming accuracy of the bridge deck.

[0033] The system achieves self-balancing of tension reaction force through the overall rigid structure of the pedestal, eliminating the need for additional reaction frames. Combined with dual synchronous hydraulic jacks, it ensures the synchronicity and accuracy of prestressing tension. An adjustable rebar limiting mechanism guides and limits the prestressed rebar throughout the tensioning process, preventing rebar misalignment and bending, and ensuring a high degree of consistency between the applied prestress value and the design value. An integrated automated cutting mechanism replaces manual hand-held cutting, completely eliminating the risk of mechanical injury, while ensuring the flatness and length consistency of the rebar cuts, facilitating subsequent component installation.

[0034] With stepless adjustment of side template spacing, adjustable cutting machine spacing, and standardized adaptability design of limiting grooves, it can quickly adapt to the prefabrication production of bridge decks with different widths, thicknesses, spans, and prestressed reinforcements, meeting the flexible production needs of multi-specification components. The integrated design significantly reduces the site area occupied by the tooling, making it suitable for prefabrication production in small factory areas. It can also meet the dual needs of fixed prefabrication in the factory and temporary prefabrication on the construction site, thus having a wider range of applications. It can adapt to the needs of high-frequency continuous prefabrication in the factory, and has significant engineering application value and economic benefits. Attached Figure Description

[0035] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1 This is a structural schematic diagram of an integrated precast platform for prestressed reinforced concrete bridge decks according to the present invention.

[0037] Figure 2 This is a partial sectional view of an integrated precast platform for prestressed reinforced concrete bridge decks according to the present invention.

[0038] Figure 3 This is a side view of the precast integrated platform for prestressed reinforced concrete bridge deck according to the present invention.

[0039] Figure 4 This is a bottom view of a limiting block in a precast integrated platform for prestressed reinforced concrete bridge deck using the pre-tensioning method, according to the present invention.

[0040] Figure 5 This is a schematic diagram of the cutting mechanism in an integrated precast platform for prestressed reinforced concrete bridge decks according to the present invention.

[0041] Figure 6 This is a schematic diagram of the adjustment mechanism in an integrated precast platform for prestressed reinforced concrete bridge decks according to the present invention.

[0042] Figure 7 This is a schematic diagram of the internal structure of the adjustment mechanism in an integrated precast platform for prestressed reinforced concrete bridge decks according to the present invention.

[0043] Figure 8 This is a schematic diagram of the synchronous drive component in an integrated precast platform for prestressed reinforced concrete bridge decks according to the present invention.

[0044] Figure 9This is a side view of the synchronous drive component in the precast integrated platform for prestressed reinforced concrete bridge deck of the present invention.

[0045] Figure 10 for Figure 9 A magnified view of a portion of point A in the middle;

[0046] Figure 11 This is a partial cross-sectional view of the synchronous drive component in a precast integrated platform for prestressed reinforced concrete bridge decks according to the present invention.

[0047] Figure 12 for Figure 11 A magnified view of a portion of point B in the middle;

[0048] Figure 13 for Figure 11 A magnified view of a portion of point C in the middle;

[0049] Figure 14 for Figure 1 A magnified view of a portion of point D.

[0050] In the diagram, 1. Platform plate; 2. Platform panel; 3. Platform block; 4. Vertical end of platform; 5. Fixed crossbeam; 6. Hydraulic jack; 7. Movable crossbeam; 8. Rebar anchor sleeve assembly; 9. Perforated sleeve; 10. Side formwork; 11. Shell; 12. Rectangular frame; 13. Sleeve; 14. Connecting column; 15. Rotating shaft one; 16. Rotating shaft two; 17. U-shaped rod; 18. U-shaped groove; 19. Sliding column; 20. Stroke hole; 21. Bearing seat one; 22. Vertical plate; 23. Worm gear; 24. Worm; 25. Bearing; 26. Bevel gear one; 27. Bevel gear two; 28. Drive shaft; 29. ​​Bearing housing two; 30. Motor one; 31. Horizontal plate; 32. Hydraulic cylinder one; 33. U-shaped support; 34. Positive and negative threaded rods; 35. Moving block; 36. Cutting machine; 37. Guide post; 38. H-beam; 39. Long strip-shaped through hole; 40. Limiting block; 41. Limiting groove; 42. Hydraulic cylinder two; 43. Guide rod; 44. Motor two; 45. Positioning plate one; 46. Positioning plate two; 47. Adjusting screw; 48. Movable rod. Detailed Implementation

[0051] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0052] Please see Figure 1-14This invention provides a precast integrated platform for prestressed reinforced concrete bridge deck using the prestressed concrete bridge deck method, comprising a platform plate 1, a platform panel 2, and two sets of platform blocks 3. The two sets of platform blocks 3 are symmetrically arranged on the top of the platform plate 1 and are spaced apart along the longitudinal direction of the platform plate 1. The platform panel 2 is supported between the two sets of platform blocks 3, and platform vertical ends 4 are fixed at both ends of the platform blocks 3.

[0053] The pedestal plate 1 is an integral thick steel plate structure, serving as the bottom load-bearing foundation of the entire pedestal. Anchor bolt holes and pedestal block mounting holes are reserved on the plate. During use, it can be easily fixed to the hardened ground of the prefabrication site with anchor bolts, eliminating the need to pour a fixed concrete pedestal and significantly reducing the investment in civil engineering in the factory area. The two sets of pedestal blocks 3 are box-shaped steel structures, symmetrically fixed to the front and rear ends of the top of the pedestal plate 1 with high-strength bolts, and arranged at intervals along the longitudinal direction of the pedestal plate 1. The spacing between the two sets of pedestal blocks 3 can be flexibly adjusted according to the design length of the bridge deck to be prefabricated, adapting to the production of components of different specifications. The platform panel 2 is a high-strength precision-machined steel template, horizontally erected between two sets of platform blocks 3, and detachably connected to the platform blocks by bolts. The top surface of the platform panel 2 is the bottom mold forming surface of the bridge deck prefabrication, with small flatness error, ensuring the flatness of the bottom surface of the bridge deck. Each platform block 3 has a vertically set platform vertical end 4 fixed to both ends of the left and right sides by high-strength bolts, providing stable installation support for the tensioning module, cutting mechanism, and limiting module. At the same time, it forms a rigid closed frame together with the platform plate and platform blocks, realizing the internal self-balance of the tension reaction force, without the need for additional reaction force structure.

[0054] Both ends of the vertical ends 4 of the two sets of platforms are connected to fixed crossbeams 5; one set of fixed crossbeams 5 is provided with a tensioning drive assembly on the side away from the platform 2, and the telescopic output end of the tensioning drive assembly is connected to a movable crossbeam 7. The movable crossbeam 7 is provided with a steel bar anchor sleeve assembly 8 on the side away from the fixed crossbeam 5, and the fixed crossbeam 5 is provided with a perforated sleeve 9 that is compatible with the steel bar anchor sleeve assembly 8 and the prestressed steel bar.

[0055] A cutting mechanism for cutting prestressed steel bars is provided between the vertical ends 4 of two adjacent sets of platforms;

[0056] The top two sides of the table panel 2 are provided with a plurality of side templates 10 evenly distributed along the longitudinal direction of the table panel 2. The top of the base block 3 is provided with an adjustment mechanism that is connected to the corresponding side templates 10 on both sides. The adjustment mechanism is used to adjust the distance between the side templates 10 arranged opposite to each other on both sides of the table panel 2.

[0057] See Figure 1-14The tensioning drive assembly includes two hydraulic jacks 6, which are symmetrically arranged with the longitudinal center line of the platform 2 as the axis of symmetry. The cylinders of the two hydraulic jacks 6 are fixedly connected to the fixed crossbeam 5, and the telescopic rods of the two hydraulic jacks 6 are fixedly connected to the movable crossbeam 7.

[0058] See Figure 1-14 The adjustment mechanism includes a housing 11 fixed to the top of the base block 3. A rectangular frame 12 arranged vertically is provided inside the housing 11. A sleeve 13 arranged horizontally is fixed at each of the four corners of the rectangular frame 12. A connecting column 14 is slidably connected inside the sleeve 13. One end of the connecting column 14 extends to the outside of the housing 11 and is fixedly connected to the side template 10 on the corresponding side.

[0059] See Figure 1-14 The housing 11 is also provided with a synchronous drive assembly, which is used to drive the four connecting columns 14 in the same housing 11 to slide synchronously towards or away from each other along the sleeve 13.

[0060] The synchronous drive assembly includes a rotating shaft 15, a rotating shaft 2 16, four sets of movable rods 48, and four sets of U-shaped rods 17.

[0061] The first rotating shaft 15 and the second rotating shaft 16 are arranged in parallel and vertically inside the housing 11 and located in the middle of one side of the rectangular frame 12. Both ends of the first rotating shaft 15 and the second rotating shaft 16 are fixedly sleeved with movable rods 48, and the movable rods 48 at both ends of the first rotating shaft 15 and the movable rods 48 at both ends of the second rotating shaft 16 are inclined in opposite directions.

[0062] Each of the four sets of movable rods 48 has a U-shaped rod 17 fixedly connected to its end, and the four sets of U-shaped rods 17 are movably inserted into the four sets of sleeves 13.

[0063] The connecting column 14 has a U-shaped groove 18 at one end away from the side template 10. A sliding column 19 is vertically fixed in the U-shaped groove 18, and the sliding column 19 moves through the through hole in the middle of the U-shaped rod 17.

[0064] See Figure 1-14 The sleeve 13 has stroke holes 20 on both sides that communicate with the internal cavity of the sleeve 13. The stroke holes 20 are used to avoid the swing stroke of the U-shaped rod 17. The first rotating shaft 15 and the second rotating shaft 16 are rotatably connected to symmetrically arranged bearing seats 21. The rectangular frame 12 has two sets of vertical plates 22 symmetrically fixed on the side facing the first rotating shaft 15. The two sets of vertical plates 22 are fixedly connected to the bearing seats 21 one by one. The middle of the first rotating shaft 15 and the second rotating shaft 16 is fixedly sleeved with worm gears 23. The two sets of worm gears 23 are meshed with a horizontally arranged worm 24. The worm 24 is horizontally rotatably installed between the two sets of vertical plates 22 through bearings 25.

[0065] A bevel gear 26 is fixed to one end of the worm gear 24 away from the worm wheel 23. A bevel gear 27 is meshed with the top of the bevel gear 26. A vertically arranged drive shaft 28 is fixed to the middle of the top of the bevel gear 27. The drive shaft 28 is rotatably connected to the rectangular frame 12 through a bearing seat 29. A motor 30 is fixed on the housing 11. The output shaft of the motor 30 is connected to the drive shaft 28 for driving the drive shaft 28 to rotate. The outer wall of the connecting column 14 is in close sliding fit with the inner wall of the sleeve 13, and the outer wall of the connecting column 14 is provided with a wear-resistant coating.

[0066] When the template spacing needs to be adjusted, start motor 30, which drives drive shaft 28 and bevel gear 27 to rotate. Bevel gear 27 meshes and drives bevel gear 26 and worm gear 24 to rotate. Worm gear 24 synchronously drives two worm wheels 23 to rotate in opposite directions, which in turn drives shaft 15 and shaft 26 to rotate in opposite directions. Shaft 15 drives the movable rods 48 at both ends to swing, and shaft 26 drives the movable rods 48 at both ends to swing. Through U-shaped rod 17, the connecting columns 14 on the left and right sides slide synchronously in opposite directions along sleeve 13, causing the side templates 10 on both sides to move away from each other, completing the mold opening action. When motor 30 rotates in the opposite direction, it can drive the side templates 10 on both sides to move synchronously towards each other, completing the mold closing action, realizing precise stepless adjustment of the spacing of the side templates 10. At the same time, the worm gear transmission has a natural reverse self-locking characteristic. After the adjustment is in place, it can automatically lock the template position. Even under the side pressure of concrete pouring, there will be no template displacement or running out problem, and no additional locking mechanism is required.

[0067] See Figure 1-14 The cutting mechanism includes a horizontal plate 31, with both ends of the horizontal plate 31 fixedly connected to the tops of two adjacent sets of vertical ends 4 of the platform. A hydraulic cylinder 32 is vertically fixed in the middle of the horizontal plate 31. A U-shaped support 33 is horizontally inverted and fixed at the bottom of the piston rod of the hydraulic cylinder 32. The U-shaped support 33 is provided with parallel arranged positive and negative threaded rods 34 and guide rods. Two sets of moving blocks 35 are symmetrically threaded on the positive and negative threaded rods 34. The moving blocks 35 slide with the guide rods. A cutting machine 36 for cutting prestressed steel bars is fixed at the bottom of the moving blocks 35. A guide post 37 is symmetrically fixed at the top of the U-shaped support 33 with the hydraulic cylinder 32 as the central axis. The guide post 37 is movably inserted through the horizontal plate 31. A motor 44 is fixed on one side of the U-shaped support 33. The output shaft of the motor 44 is coaxially fixedly connected to the end of the positive and negative threaded rods 34.

[0068] After the prestressed steel bars are tensioned and locked, hydraulic cylinder 32 is activated to lower the U-shaped support 33, causing the cutting blade of the cutting machine 36 to descend to the designed cutting height position of the prestressed steel bars. Motor 44 is activated to rotate the positive and negative threaded rods 34, driving the two moving blocks 35 to move synchronously, adjusting the distance between the two cutting machines 36 to match the arrangement range of the steel bars to be cut. The cutting machine 36 is activated, and the cutting feed is controlled by hydraulic cylinder 32. In conjunction with the lateral movement of the cutting machine, the automated synchronous cutting of multiple prestressed steel bars is completed. For multiple rows of densely arranged steel bars, the cutting machine position can be adjusted in stages to complete the cutting operation in batches. The entire process does not require manual hand operation, completely eliminating the safety hazards of manual cutting. At the same time, the cutting accuracy is much higher than that of manual operation, ensuring the flatness and reserved length of all steel bar cuts are consistent.

[0069] See Figure 1-14 An H-shaped steel beam 38 is fixedly connected to the bottom of the vertical ends 4 of two adjacent sets of the platform. A long, narrow through hole 39 is provided on the top of the H-shaped steel beam 38 on the side opposite to the fixed crossbeam 5. A limiting block 40 is vertically and movably connected within the long, narrow through hole 39. A limiting groove 41, corresponding one-to-one with the perforated sleeve 9, is provided on the top of the limiting block 40. A hydraulic cylinder 42 is fixed to the middle of the bottom end of the limiting block 40. The bottom end of the hydraulic cylinder 42 is fixedly connected to the inner bottom of the H-shaped steel beam 38, used to drive the limiting block 40 to move vertically up and down. Guide rods 43 are symmetrically fixed to the inner bottom of the H-shaped steel beam 38, and the guide rods 43 movably pass through the limiting block 40.

[0070] After the prestressed steel bars are installed, hydraulic cylinder 42 is activated to raise the limiting block 40, causing the prestressed steel bars to fall into the corresponding limiting groove 41. This provides bottom support and lateral limitation for the steel bars, preventing sagging, deviation, and bending of long-distance prestressed steel bars during tensioning and ensuring tensioning accuracy. During steel bar cutting, the limiting groove can rigidly fix the steel bars, preventing them from shaking during cutting and further improving cutting accuracy and operational safety.

[0071] See Figure 1-14 On the side of the side templates 10 located on both sides of the table panel 2, which are far apart from each other, there are horizontally fixed positioning plates 45 and 46 extending towards the middle of the table panel 2. The positioning plates 45 and 46 are vertically offset, and the positioning plates 45 and 46 are threadedly connected to adjusting screws 47.

[0072] In use, according to the design parameters of the bridge deck to be prefabricated, the bolt assembly of the pier plate, pier block, pier vertical end, and fixed crossbeam is completed. The pier panel is hoisted into place and fixed, completing the main assembly of the pier. The assembled pier is then simply fixed to the hardened ground of the prefabrication site with anchor bolts. The tooling deployment can be completed without large-scale civil construction.

[0073] Based on the design width of the bridge deck, the motor 30 of the adjustment mechanism is started, driving the side templates 10 on both sides to move synchronously and precisely adjust to the design width size; then the joint gap and verticality of the adjacent side templates are finely adjusted by adjusting the screw 47 to complete the support of the casting cavity. The whole process does not require manual prying or adjusting the top screw, and the efficiency and accuracy of the formwork are greatly improved.

[0074] The ordinary steel reinforcement skeleton of the bridge deck is tied in the template cavity, and the prestressed steel bars are inserted according to the design position. The fixed end of the steel bar is anchored to the fixed crossbeam at the rear end, and the tensioning end passes through the through sleeve 9 of the fixed crossbeam at the front end and is locked to the movable crossbeam 7 by the steel bar anchor sleeve assembly 8. The hydraulic cylinder 42 is started, which drives the limit block 40 to rise and supports and limits the prestressed steel bar through the limit groove 41. Two synchronous hydraulic jacks 6 are started to tension the prestressed steel bar in stages according to the design tensioning procedure. After the design tension value is reached, the anchor is locked under pressure to complete the application of prestress.

[0075] After tensioning and locking are completed, the cutting mechanism is started to complete the automated synchronous cutting of the exposed prestressed steel bars at the tensioning end. After cutting is completed, the cutting mechanism and the limiting mechanism are reset.

[0076] Pour the bridge deck concrete into the mold cavity after the formwork has been erected. After vibration and finishing, steam curing or natural curing is carried out according to the design requirements.

[0077] After the concrete strength of the bridge deck reaches the design release requirement, the prestressed steel bars are released; the motor 30 is started to rotate in the opposite direction, driving the side formwork 10 on both sides to move synchronously in opposite directions to complete the demolding operation. The precast bridge deck can then be lifted and transported by the lifting equipment, and the platform can directly enter the precast cycle of the next bridge deck.

[0078] Once the prefabrication task is completed, the connecting bolts of each component of the pedestal can be removed, allowing for quick disassembly into independent modules. This facilitates transport to other projects for reassembly and reuse, significantly improving tooling utilization and reducing overall costs.

[0079] Although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A precast integrated platform for prestressed reinforced concrete bridge deck using the prestressed concrete method, comprising a platform plate (1), a platform panel (2), and two sets of platform blocks (3), wherein the two sets of platform blocks (3) are symmetrically arranged on the top of the platform plate (1) and spaced apart along the longitudinal direction of the platform plate (1), the platform panel (2) is erected between the two sets of platform blocks (3), and both ends of the platform blocks (3) are fixedly provided with platform vertical ends (4); characterized in that: Both ends of the vertical ends (4) of the two sets of platforms are connected to fixed crossbeams (5); one set of fixed crossbeams (5) is provided with a tensioning drive assembly on the side away from the platform (2), and the telescopic output end of the tensioning drive assembly is connected to a movable crossbeam (7). The movable crossbeam (7) is provided with a steel bar anchor sleeve assembly (8) on the side away from the fixed crossbeam (5), and the fixed crossbeam (5) is provided with a perforated sleeve (9) that is compatible with the steel bar anchor sleeve assembly (8) and the prestressed steel bar. A cutting mechanism for cutting prestressed steel bars is provided between the vertical ends (4) of two adjacent sets of platforms; The top two sides of the table panel (2) are provided with a number of side templates (10) evenly distributed along the longitudinal direction of the table panel (2). The top of the base block (3) is provided with an adjustment mechanism that is connected to the corresponding side templates (10) on both sides. The adjustment mechanism is used to adjust the distance between the side templates (10) arranged opposite to each other on both sides of the table panel (2).

2. The precast integrated pedestal for pre-tensioned prestressed concrete bridge deck slab according to claim 1, characterized in that, The tensioning drive assembly includes two hydraulic jacks (6). The two hydraulic jacks (6) are symmetrically arranged with the longitudinal center line of the platform (2) as the axis of symmetry. The cylinders of the two hydraulic jacks (6) are fixedly connected to the fixed crossbeam (5), and the telescopic rods of the two hydraulic jacks (6) are fixedly connected to the movable crossbeam (7).

3. The precast integrated pedestal for pre-tensioned prestressed concrete bridge deck slab according to claim 2, characterized in that, The adjustment mechanism includes a housing (11) fixed to the top of the base block (3). A rectangular frame (12) is arranged vertically inside the housing (11). A sleeve (13) is fixed at each of the four corners of the rectangular frame (12). A connecting column (14) is slidably connected inside the sleeve (13). One end of the connecting column (14) extends to the outside of the housing (11) and is fixedly connected to the side template (10) on the corresponding side. The housing (11) is also provided with a synchronous drive assembly, which is used to drive the four connecting columns (14) in the same housing (11) to slide synchronously towards or away from each other along the sleeve (13).

4. The precast integrated platform for prestressed reinforced concrete bridge deck according to claim 3, characterized in that, The synchronous drive assembly includes a rotating shaft one (15), a rotating shaft two (16), four sets of movable rods (48) and four sets of U-shaped rods (17). The first rotating shaft (15) and the second rotating shaft (16) are arranged in parallel and vertically inside the housing (11) and located in the middle of one side of the rectangular frame (12). Both ends of the first rotating shaft (15) and the second rotating shaft (16) are fixedly sleeved with movable rods (48), and the movable rods (48) at both ends of the first rotating shaft (15) and the movable rods (48) at both ends of the second rotating shaft (16) are inclined in opposite directions. Each of the four sets of movable rods (48) has a set of U-shaped rods (17) fixedly connected to its end, and the four sets of U-shaped rods (17) are movably inserted into the four sets of sleeves (13); The connecting column (14) has a U-shaped groove (18) at one end away from the side template (10). A sliding column (19) is vertically fixed in the U-shaped groove (18). The sliding column (19) moves through the through hole in the middle of the U-shaped rod (17).

5. The precast integrated platform for prestressed reinforced concrete bridge deck according to claim 4, characterized in that, The sleeve (13) has stroke holes (20) on both sides that communicate with the internal cavity of the sleeve (13). The stroke holes (20) are used to avoid the swing stroke of the U-shaped rod (17). The first rotating shaft (15) and the second rotating shaft (16) are rotatably connected to symmetrically arranged bearing seats (21). The rectangular frame (12) is symmetrically fixed with two sets of vertical plates (22) on the side facing the first rotating shaft (15). The two sets of vertical plates (22) are fixedly connected to the bearing seats (21) one by one. The middle of the first rotating shaft (15) and the second rotating shaft (16) are fixedly sleeved with worm gears (23). The two sets of worm gears (23) are meshed together with a horizontally arranged worm (24). The worm (24) is installed horizontally between the two sets of vertical plates (22) through the bearing (25).

6. The precast integrated platform for prestressed reinforced concrete bridge deck according to claim 5, characterized in that, The worm (24) is fixed with a bevel gear one (26) at the end away from the worm wheel (23). The top of the bevel gear one (26) is meshed with a bevel gear two (27). The top center of the bevel gear two (27) is fixed with a vertically arranged drive shaft (28). The drive shaft (28) is rotatably connected to the rectangular frame (12) through a bearing seat two (29). The housing (11) is fixed with a motor one (30). The output shaft of the motor one (30) is connected to the drive shaft (28) for driving the drive shaft (28) to rotate. The outer wall of the connecting column (14) is in close sliding fit with the inner wall of the sleeve (13), and the outer wall of the connecting column (14) is provided with a wear-resistant coating.

7. The precast integrated platform for prestressed reinforced concrete bridge deck according to claim 6, characterized in that, The cutting mechanism includes a horizontal plate (31), the two ends of which are fixedly connected to the top of the vertical ends (4) of two adjacent sets of platforms. A hydraulic cylinder (32) is vertically fixed in the middle of the horizontal plate (31). A U-shaped support (33) is horizontally inverted fixed at the bottom of the piston rod of the hydraulic cylinder (32). The U-shaped support (33) is provided with parallel arranged positive and negative threaded rods (34) and guide rods. Two sets of moving blocks (35) are symmetrically threaded on the positive and negative threaded rods (34). The movable block (35) is slidably engaged with the guide rod, and a cutting machine (36) for cutting prestressed steel bars is fixed at the bottom of the movable block (35); a guide column (37) is symmetrically fixed at the top of the U-shaped support (33) with the hydraulic cylinder (32) as the central axis, and the guide column (37) is movably connected through the horizontal plate (31); a motor (44) is fixed on one side of the U-shaped support (33), and the output shaft of the motor (44) is coaxially fixedly connected to the end of the positive and negative threaded rod (34).

8. The precast integrated platform for prestressed reinforced concrete bridge deck according to claim 7, characterized in that, The bottom of the two adjacent sets of the vertical ends (4) of the platform is fixedly connected to an H-shaped steel beam (38). The top of the H-shaped steel beam (38) is provided with a long strip-shaped through hole (39) on the side away from the fixed crossbeam (5). A limit block (40) is vertically movably connected in the long strip-shaped through hole (39). The top of the limit block (40) is provided with a limit groove (41) that corresponds to the perforated sleeve (9).

9. The precast integrated platform for prestressed reinforced concrete bridge deck according to claim 8, characterized in that, A hydraulic cylinder (42) is fixed at the bottom center of the limiting block (40). The bottom of the cylinder body of the hydraulic cylinder (42) is fixedly connected to the inner bottom of the H-shaped steel beam (38) to drive the limiting block (40) to move vertically up and down. A guide rod (43) is symmetrically fixed at the inner bottom of the H-shaped steel beam (38). The guide rod (43) is movably inserted through the limiting block (40).

10. The precast integrated platform for prestressed reinforced concrete bridge deck according to claim 9, characterized in that, On the side of the side templates (10) located on both sides of the table panel (2) that are far apart from each other, there are horizontally fixed positioning plates one (45) and two (46) extending towards the middle of the table panel (2). The positioning plates one (45) and two (46) are vertically offset, and the positioning plates one (45) and two (46) are threadedly connected to adjusting screws (47).

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