A method for manufacturing a precast T-beam

Abstract

The application provides a prefabricated T-beam manufacturing method, and discards the traditional template hoisting and disassembling mode through the structure design which can be automatically disassembled and folded, realizes the in-situ opening and closing and quick resetting of side molds and end molds, greatly shortens the template disassembling time, significantly improves the T-beam prefabrication construction efficiency, relies on the power clamping and the speed reducer self-locking fixing of the template, saves a large number of fasteners, reduces the labor intensity, cooperates with the automatic vibration and intelligent control system, reduces the high-altitude operation, improves the vibration uniformity and construction safety, has high utilization rate of the template, effectively shortens the production cycle, adapts to the efficient production demand of the factory fixed prefabrication field, and solves the problems of low disassembling efficiency of the traditional T-beam prefabrication template and difficulty in meeting the factory and integrated prefabrication production.

Description

Technical Field

[0001] This invention relates to the field of T-beam prefabrication, and in particular to a method for manufacturing prefabricated T-beams. Background Technology

[0002] In the field of prestressed concrete T-beam prefabrication construction, traditional construction techniques generally use fixed prefabrication platforms in conjunction with split formwork for on-site assembly. The installation and dismantling of formwork largely rely on hoisting equipment in conjunction with manual labor, which results in cumbersome procedures and long time consumption.

[0003] During construction, the side formwork and end formwork need to be hoisted into place piece by piece and repeatedly fixed with fasteners such as tie rods and bolts. After dismantling, the formwork also needs to be hoisted to a designated area for storage and cleaning. It is impossible to quickly reset it in its original position, which seriously restricts the efficiency of continuous production. Traditional vibration operation relies on manual operation of hand-held vibration equipment on top of the formwork, which is labor-intensive, has low operational safety, and the vibration quality is significantly affected by human factors.

[0004] The aforementioned problems result in low efficiency in the assembly and disassembly of traditional T-beam precast formwork, making it difficult to meet the needs of factory-based and intensive precast production. Therefore, this solution provides a construction method that can automatically disassemble and reassemble the formwork and reuse it in situ, in order to solve the problems of low efficiency and long construction cycle of traditional formwork hoisting and disassembly. Summary of the Invention

[0005] The main objective of this invention is to provide a method for manufacturing precast T-beams, which solves the problem of low assembly and disassembly efficiency of traditional T-beam precast templates, making it difficult to meet the requirements of factory-based and integrated precast production.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a method for manufacturing precast T-beams, the method comprising: S1. Cast a precast platform in the precast yard and install the closing components on both sides of the precast platform. S2. Install the template component on the closing component, and set detachable end template components at both ends of the template component; S3. Connect the tensioning component to the outside of the end formwork component. After the tensioning component is installed, erect the T-beam reinforcement cage inside the formwork component. S4. A corrugated pipe is installed through the steel cage of the T-beam, and the corrugated pipe is connected to the end formwork assembly. S5. After completing the corrugated pipe connection, pour concrete inside the formwork assembly. After the concrete is poured, install the vibrating assembly on top of the formwork assembly. S6. After the concrete is vibrated using the vibrating assembly and the formwork assembly, wait for the concrete to initially set and then cure it. After curing, remove the formwork assembly and the end formwork assembly from the initially set concrete. The removed formwork assembly and end formwork assembly can then be cleaned for the next use. S7. Insert the tension cable inside the corrugated pipe and install the tension anchor plate. Then use the tensioning assembly to tension the tension cable to the preset stress state. After tensioning is completed, cut off the excess tension cable. S8. After the precast T-beam is tensioned and detached, repeat steps S2-S8 to complete the cyclical production of the T-beam.

[0007] In the preferred embodiment, in step S1, the closing component includes a closing guide rail, a sliding closing base plate is provided on the closing guide rail, a closing power is provided on the closing base plate, and a side mold support is provided on one side of the closing base plate, the side mold support is used to support the bottom of the template component. The closing power system includes a motor, a speed reducer, and a drive wheel, which is used to move on the closing guide rail.

[0008] In the preferred embodiment, in step S1, the precast platform is precast using concrete, and tension positioning grooves are provided at both ends of the precast platform for connecting tensioning components. Step S1.1: Cast a precast platform in the precast yard. Install steel pads at the top two corners of the precast platform to avoid affecting the sealing of the template components. A bottom template needs to be laid on top of the precast platform during casting. Step S1.2: Symmetrically arrange closing guide rails on both sides of the precast platform so that the closing base plate can slide on the closing guide rails.

[0009] In the preferred embodiment, in step S2, the template assembly includes a template support beam, a template column is provided on one side of the template support beam, a side template is provided on the other side, a side template vibrator is provided on the outer wall of the side template, and a side template top plate is provided on the top of the side template. The top of the formwork column is equipped with a formwork top beam, and the top of the formwork top beam is equipped with a top beam guide rail, which is used to install the vibrating assembly; Step S2.1: Connect the formwork column to the closing base plate, install the formwork support beam on one side of the formwork column, and install the side formwork on one side of the formwork support beam. Step S2.2: After the side formwork is installed, start the closing power to make the side formwork fit against one side of the precast platform, and check the tightness of the fit between the side formwork and the precast platform.

[0010] In the preferred embodiment, in step S3, the end mold assembly includes an end mold main frame, an end mold top plate is provided above the end mold main frame, a protruding plate is provided on one side of the end mold main frame, an anchor plate guide hole is provided on the protruding plate, and a detachable anchor plate guide cylinder is provided in the anchor plate guide hole. The top plate of the end mold is provided with symmetrical side end plate grooves. The main frame of the end mold is provided with a threaded hole on the outward side. The threaded hole is used to connect with the tensioning component. The side end plate groove is provided with a detachable side end baffle, which fits against the top plate of the side mold.

[0011] In the preferred embodiment, in step S3, the tensioning assembly includes a tensioning base, a tensioning column is provided above the tensioning base, a walking power source is provided below the tensioning column, a tensioning connecting rod is provided on one side of the tensioning column, and a through hole is provided at the front end of the tensioning connecting rod for connecting with the end mold assembly. The walking power includes a motor, a reducer and a drive wheel. There are also lifting guide rails between the tensioning connecting rods, and a lifting slide that can move up and down is provided between the lifting guide rails. The lifting slide is equipped with a tensioning jack. A lifting motor is also provided above the tensioning connecting rod. The output shaft end of the lifting motor is equipped with a lifting screw. The lifting screw is engaged with the lifting slide and is used to drive the lifting slide to move up and down. One side of the tensioning jack is also equipped with a coaxial, detachable load-bearing cylinder.

[0012] In the preferred embodiment, step S3.1 involves connecting the threaded hole of the end mold main frame to the through hole on the tensioning connecting rod using bolts; Step S3.2: The construction personnel use automatic control of the walking power to move the tensioning component carrying the end formwork main frame to one end of the formwork component and place the end formwork component between the formwork components. Step S3.3: The tensioning component adjusts its posture and moves the end mold main frame to the preset position of the end mold component before stopping.

[0013] In the preferred embodiment, in steps S4-S8, the vibrating assembly includes a vibrating transverse plate, a vibrating guide rail is provided on the vibrating transverse plate, a slidable transverse seat is provided on the vibrating guide rail, and a retractable vibrating rod is provided on the transverse seat. One side of the vibratory transverse plate is also provided with transverse force one, which is used to make the vibratory assembly move on the top beam guide rail. One side of the transverse seat is also provided with transverse force two, which is used to drive the transverse seat to move on the vibratory guide rail. Both transverse force one and transverse force two include a motor, a reducer and a drive wheel.

[0014] In the preferred embodiment, a vibratory collection column is provided on the transverse moving seat, a sliding cavity is provided inside the vibratory collection column, multiple telescopic guide rods are provided inside the sliding cavity, a telescopic motor is provided at the top of the vibratory collection column, and a telescopic lead screw is provided at the output shaft end of the telescopic motor. The sliding cavity is also equipped with a sliding telescopic guide seat, which is slidably connected to the telescopic guide rod. The telescopic guide seat is engaged with the telescopic screw rod, which drives the telescopic guide seat to slide up and down. A vibrator is provided below the telescopic guide seat, and a through groove is provided on the vibrating transverse plate. The vibrator is telescopically and movable in the through groove. In step S6, after the end formwork assembly is detached from the initial set concrete, a groove will be reserved for placing the tensioning anchor plate.

[0015] In step S7, the tensioning jack in the tensioning assembly can move up and down to tension the tensioning cables at different heights.

[0016] This invention provides a method for manufacturing precast T-beams, which has the following advantages: The invention, through a structural design that allows for automatic disassembly and closure, eliminates the traditional formwork hoisting and disassembly methods, enabling the side and end formwork to open and close in situ and quickly reset, significantly shortening the formwork disassembly and assembly time and greatly improving the efficiency of T-beam precast construction. The formwork is fixed by power clamping and a reducer self-locking mechanism, eliminating the need for numerous fasteners and reducing labor intensity. Combined with an automated vibration and intelligent control system, it reduces high-altitude operations, improves vibration uniformity and construction safety, and achieves high formwork utilization, effectively shortening the production cycle and meeting the high-efficiency production needs of factory-based fixed prefabrication yards. Attached Figure Description

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is an axonometric view of the T-beam manufacturing apparatus of the present invention; Figure 2 This is an isometric view of the template component of the present invention; Figure 3 This is a cross-sectional view of the template component of the present invention; Figure 4 This is a front view of one end of the template component of the present invention; Figure 5 This is an isometric view of the tensioning assembly and end mold assembly of the present invention; Figure 6 This is a cross-sectional schematic diagram of the tensioning component and the end mold component of the present invention; Figure 7 This is an isometric view of the tensioning assembly and end mold assembly of the present invention from another direction; Figure 8 This is a partial isometric view of the tensioning assembly of the present invention; Figure 9 This is an isometric view of the end mold assembly of the present invention from another direction; Figure 10 This is a schematic diagram of the corrugated pipes arranged inside the template assembly of the present invention; Figure 11 This is a schematic diagram of concrete pouring inside the template component of the present invention; Figure 12 This is a partial isometric view of the vibratory compaction assembly of the present invention; Figure 13 This is a cross-sectional schematic diagram of the vibrating assembly of the present invention; Figure 14 This is a schematic diagram of the tension cables interspersed within the template component of the present invention; Figure 15 This is a schematic diagram of the tensioning cable of the tensioning component of the present invention; Figure 16This is a schematic diagram of the precast T-beam forming post-cast groove of the present invention.

[0018] In the diagram: Closing assembly 1; Closing guide rail 101; Closing base plate 102; Closing power 103; Side formwork support 104; Formwork assembly 2; Formwork support beam 201; Formwork column 202; Formwork top beam 203; Side formwork 204; Side formwork top plate 205; Top beam guide rail 206; Side formwork vibrator 207; Side end baffle 208; Tensioning assembly 3; Tensioning base 301; Traveling power 302; Tensioning column 303; Tensioning connecting rod 304; Tensioning jack 305; Lifting motor 306; Load-bearing cylinder 307; Lifting guide rail 308; Lifting screw 309; Tensioning positioning plate 310; Through hole 311; Lifting slide 3 12; End mold assembly 4; End mold main frame 401; End mold top plate 402; Side end plate groove 403; Convex plate 404; Anchor plate guide hole 405; Anchor plate guide cylinder 406; Threaded hole 407; Vibration assembly 5; Vibration transverse plate 501; Vibration guide rail 502; Transverse movement force one 503; Transverse seat 504; Vibration storage column 505; Telescopic motor 506; Through slide 507; Transverse movement force two 508; Vibration rod 509; Telescopic guide rod 510; Sliding cavity 511; Telescopic guide seat 512; Telescopic screw rod 513; Precast platform 6; Tensioning positioning groove 601; Tensioning anchor plate 7; Post-pouring groove 8; Tensioning cable 9; Corrugated pipe 10. Detailed Implementation

[0019] Example 1 like Figure 1-16 As shown, a method for manufacturing a precast T-beam includes: S1. Cast the precast platform 6 in the precast yard and install the closing components 1 on both sides of the precast platform 6. S2. Install template component 2 on closing component 1, and set detachable end mold components 4 at both ends of template component 2; S3. Connect the tensioning component 3 to the outside of the end formwork component 4. After the tensioning component 3 is installed, erect the T-beam reinforcement cage inside the formwork component 2. S4. A corrugated pipe 10 is installed through the T-beam reinforcement cage, and the corrugated pipe 10 is connected to the end formwork assembly 4. S5. After completing the connection of the corrugated pipe 10, pour concrete inside the formwork assembly 2. After the concrete is poured, install the vibrating assembly 5 on top of the formwork assembly 2. S6. After the concrete is vibrated using the vibrating assembly 5 and the formwork assembly 2, wait for the concrete to initially set and then cure it. After curing, remove the formwork assembly 2 and the end formwork assembly 4 from the initially set concrete. After removal, the formwork assembly 2 and the end formwork assembly 4 can be cleaned for the next use. S7. Insert the tension cable 9 inside the bellows 10 and install the tension anchor plate 7. Then use the tensioning assembly 3 to tension the tension cable 9 to the preset stress state. After tensioning is completed, cut off the excess tension cable 9. S8. After the precast T-beam is tensioned and detached, repeat steps S2-S8 to complete the cyclical production of the T-beam.

[0020] In the preferred embodiment, in step S1, the closing component 1 includes a closing guide rail 101, a sliding closing base plate 102 is provided on the closing guide rail 101, a closing power 103 is provided on the closing base plate 102, and a side mold support 104 is also provided on one side of the closing base plate 102, which is used to support the bottom of the template component 2. The closing power 103 includes a motor, a reducer, and a drive wheel, which is used to move on the closing guide rail 101.

[0021] In the preferred embodiment, in step S1, the precast platform 6 is precast using concrete, and tension positioning grooves 601 are provided at both ends of the precast platform 6. The tension positioning grooves 601 are used to connect the tensioning components 3. Step S1.1: Cast the precast platform 6 in the precast yard. Install steel pads at the top two corners of the precast platform 6 to avoid affecting the sealing of the formwork assembly 2. During casting, a bottom formwork needs to be laid on top of the precast platform 6. Step S1.2: The closing guide rails 101 are symmetrically arranged on both sides of the precast platform 6 so that the closing base plate 102 can slide on the closing guide rails 101.

[0022] In the preferred embodiment, in step S2, the template assembly 2 includes a template support beam 201, a template column 202 is provided on one side of the template support beam 201, a side template 204 is provided on the other side, a side template vibrator 207 is provided on the outer wall of the side template 204, and a side template top plate 205 is provided on the top of the side template 204. The top of the template column 202 is provided with a template top beam 203, and the top of the template top beam 203 is provided with a top beam guide rail 206. The top beam guide rail 206 is used to install the vibrating component 5. Step S2.1: Connect the template column 202 to the closing base plate 102, install the template support beam 201 on one side of the template column 202, and install the side template 204 on one side of the template support beam 201. Step S2.2: After the side template 204 is installed, start the closing power 103 to make the side template 204 fit against one side of the precast platform 6, and check the tightness of the fit between the side template 204 and the precast platform 6.

[0023] In the preferred embodiment, in step S3, the end mold assembly 4 includes an end mold main frame 401, an end mold top plate 402 is provided above the end mold main frame 401, a protruding plate 404 is provided on one side of the end mold main frame 401, an anchor plate guide hole 405 is provided on the protruding plate 404, and a detachable anchor plate guide cylinder 406 is provided in the anchor plate guide hole 405. The end mold top plate 402 is provided with symmetrical side end plate grooves 403. The end mold main frame 401 is provided with a threaded hole 407 on the outward side. The threaded hole 407 is used to connect with the tensioning component 3. The side end plate groove 403 is provided with a detachable side end baffle 208, which is in contact with the side mold top plate 205.

[0024] In the preferred embodiment, in step S3, the tensioning assembly 3 includes a tensioning base 301, a tensioning column 303 is provided above the tensioning base 301, a walking power source 302 is provided below the tensioning column 303, a tensioning connecting rod 304 is provided on one side of the tensioning column 303, and a through hole 311 is provided at the front end of the tensioning connecting rod 304 for connecting with the end mold assembly 4; The walking power 302 includes a motor, a reducer and a drive wheel. A lifting guide rail 308 is also provided between the tensioning connecting rods 304. A lifting slide 312 that can move up and down is provided between the lifting guide rails 308. A tensioning jack 305 is provided on the lifting slide 312. Above the tensioning connecting rod 304, there is also a lifting motor 306. The output shaft end of the lifting motor 306 is provided with a lifting screw 309. The lifting screw 309 is meshed with the lifting slide 312 and is used to drive the lifting slide 312 to move up and down. One side of the tensioning jack 305 is also equipped with a coaxial and detachable load-bearing cylinder 307.

[0025] In the preferred embodiment, in step S3.1, the threaded hole 407 of the end mold main frame 401 is connected to the through hole 311 on the tensioning connecting rod 304 by bolts; Step S3.2: The construction personnel use the automatic control walking power 302 to move the tensioning component 3 carrying the end formwork main frame 401 to one end of the template component 2 and place the end formwork component 4 between the template components 2. Step S3.3: The tensioning component 3 adjusts its posture to move the end mold main frame 401 to the preset position of the end mold component 4 and then stops.

[0026] In the preferred embodiment, in steps S4-S8, the vibrating assembly 5 includes a vibrating transverse plate 501, a vibrating guide rail 502 is provided on the vibrating transverse plate 501, a slidable transverse seat 504 is provided on the vibrating guide rail 502, and a retractable vibrating rod 509 is provided on the transverse seat 504. A transverse force 503 is provided on one side of the transverse moving plate 501. The transverse force 503 is used to make the vibrating assembly 5 move on the top beam guide rail 206. A transverse force 508 is provided on one side of the transverse moving seat 504. The transverse force 508 is used to drive the transverse moving seat 504 to move on the vibrating guide rail 502. Both the transverse force 503 and the transverse force 508 include a motor, a reducer and a drive wheel.

[0027] In the preferred embodiment, the transverse shift seat 504 is provided with a vibratory storage column 505, the vibratory storage column 505 is provided with a sliding cavity 511 inside, the sliding cavity 511 is provided with a plurality of telescopic guide rods 510 inside, the top of the vibratory storage column 505 is provided with a telescopic motor 506, and the output shaft end of the telescopic motor 506 is provided with a telescopic lead screw 513. The sliding cavity 511 is also provided with a sliding telescopic guide seat 512. The telescopic guide seat 512 is slidably connected to the telescopic guide rod 510. The telescopic guide seat 512 is engaged with the telescopic screw rod 513. The telescopic screw rod 513 drives the telescopic guide seat 512 to slide up and down. A vibrating rod 509 is provided below the telescopic guide seat 512. The vibrating transverse plate 501 is also provided with a through groove 507. The vibrating rod 509 is telescopically and movable in the through groove 507. In step S6, after the end formwork assembly 4 is detached from the initial set concrete, a groove will be reserved for placing the tensioning anchor plate 7.

[0028] In step S7, the tensioning jack 305 in the tensioning assembly 3 can move up and down to tension the tensioning cables 9 at different heights.

[0029] Example 2 Further explanation in conjunction with Example 1, such as Figure 1-16 The specific implementation method of a prefabricated T-beam manufacturing method is as follows: S1. Cast the precast platform 6 in the precast yard and install the closing components 1 on both sides of the precast platform 6. In this step, the closing assembly 1 includes a closing guide rail 101, a sliding closing base plate 102 on the closing guide rail 101, a closing power 103 on the closing base plate 102, and a side mold support 104 on one side of the closing base plate 102, which is used to support the bottom of the template assembly 2; the closing power 103 includes a motor, a reducer and a drive wheel, which is used to move on the closing guide rail 101.

[0030] The precast platform 6 is made of precast concrete. Tensioning positioning grooves 601 are provided at both ends of the precast platform 6. The tensioning positioning grooves 601 are used to connect the tensioning components 3. Steel pads are installed at the top two corners of the precast platform 6 to avoid affecting the sealing of the formwork assembly 2. During pouring, a fixed bottom formwork is laid on top of the precast platform 6. A closing guide rail 101 is symmetrically arranged on both sides of the precast platform 6 so that the closing base plate 102 can slide on the closing guide rail 101.

[0031] S2. Install template component 2 on closing component 1, and set detachable end mold components 4 at both ends of template component 2; In this step, the template assembly 2 includes a template support beam 201, a template column 202 is provided on one side of the template support beam 201, a side template 204 is provided on the other side, a side template vibrator 207 is provided on the outer wall of the side template 204, and a side template top plate 205 is provided on the top of the side template 204. The top of the template column 202 is provided with a template top beam 203, and the top of the template top beam 203 is provided with a top beam guide rail 206. The top beam guide rail 206 is used to install the vibrating component 5. The template column 202 is connected to the closing base plate 102. A template support beam 201 is installed on one side of the template column 202, and a side template 204 is installed on one side of the template support beam 201. After the side template 204 is installed, start the closing power 103 to make the side template 204 fit against one side of the precast platform 6. Check the tightness of the fit between the side template 204 and the precast platform 6, and fix it by relying on the power clamping and the self-locking of the reducer.

[0032] S3. Connect the tensioning component 3 to the outside of the end formwork component 4. After the tensioning component 3 is installed, erect the T-beam reinforcement cage inside the formwork component 2. In this step, the end mold assembly 4 includes an end mold main frame 401, an end mold top plate 402 is provided above the end mold main frame 401, a protruding plate 404 is provided on one side of the end mold main frame 401, an anchor plate guide hole 405 is provided on the protruding plate 404, and a detachable anchor plate guide cylinder 406 is provided in the anchor plate guide hole 405. The end mold top plate 402 is provided with symmetrical side end plate grooves 403. The end mold main frame 401 is provided with a threaded hole 407 on the outward side. The threaded hole 407 is used to connect with the tensioning component 3. The side end plate groove 403 is provided with a detachable side end baffle 208, which is in contact with the side mold top plate 205.

[0033] The tensioning assembly 3 includes a tensioning base 301, a tensioning column 303 above the tensioning base 301, a walking power source 302 below the tensioning column 303, a tensioning connecting rod 304 on one side of the tensioning column 303, and a through hole 311 at the front end of the tensioning connecting rod 304 for connecting to the end mold assembly 4. The walking power 302 includes a motor, a reducer and a drive wheel. A lifting guide rail 308 is also provided between the tensioning connecting rods 304. A lifting slide 312 that can move up and down is provided between the lifting guide rails 308. A tensioning jack 305 is provided on the lifting slide 312. Above the tensioning connecting rod 304, there is also a lifting motor 306. The output shaft end of the lifting motor 306 is equipped with a lifting screw 309. The lifting screw 309 is meshed with the lifting slide 312 and is used to drive the lifting slide 312 to move up and down. On one side of the tensioning jack 305, there is also a coaxial detachable load-bearing cylinder 307.

[0034] The threaded hole 407 of the end mold main frame 401 is connected to the through hole 311 on the tensioning connecting rod 304 by bolts; the walking power 302 is manually controlled by the existing control system to move the tensioning component 3 carrying the end mold main frame 401 to one end of the template component 2, and the end mold component 4 is placed between the template components 2. After the tensioning component 3 adjusts its posture and moves the end mold main frame 401 to the preset position, it stops, thus achieving end mold positioning and end template alignment.

[0035] S4. A corrugated pipe 10 is installed through the T-beam reinforcement cage, and the corrugated pipe 10 is connected to the end formwork assembly 4. The corrugated pipe 10 is fixed in the designed position, and its end is smoothly connected to the inner hole of the anchor plate guide cylinder 406 to ensure the pipe is sealed and the position is accurate, so as to meet the requirements of subsequent cable threading and tensioning. The anchor plate guide cylinder 406 protrudes inward with a convex plate 404, and the protruding part is used to form the placement groove of the tensioning anchor plate 7.

[0036] S5. After completing the connection of the corrugated pipe 10, pour concrete inside the formwork assembly 2. After the concrete is poured, install the vibrating assembly 5 on top of the formwork assembly 2. Concrete is centrally mixed at the existing batching plant, transported to the site by tanker trucks, and poured after passing inspection; Vibration component 5 is equipped with the existing intelligent control system and visual recognition system, which is controlled by the central control console to achieve fully automatic walking, automatic extension and retraction, and automatic vibration, reducing the number of construction personnel working on the top of the formwork. The existing intelligent control system adopts a conventional industrial PLC control system in this field, including a central control console, a data acquisition module, a motion control module, a communication module, and an execution drive module. The central control console has a built-in processor, memory, touch display unit, and signal interaction interface, which can uniformly schedule and close-loop control the movement, extension, and vibration start and stop of the vibrating component 5.

[0037] The existing visual recognition system includes an industrial high-definition camera, an image acquisition unit, an image processing unit, a standard image library unit, and a comparison and judgment unit. It is a mature visual inspection technology in the field of concrete construction. The industrial high-definition camera is installed on the vibrating component 5 or the top beam of the formwork 203 and moves synchronously with the vibrating component 5 to take pictures and identify the concrete pouring surface in real time, and obtain the surface state image of the current pouring area. After preprocessing, the image is transmitted to the image processing unit and compared with the pre-stored images of compacted and uncompacted states in the standard image library unit. The system determines whether the area needs to be vibrated by parameters such as grayscale features, bubble area, and surface flatness. After confirming whether to vibrate at this location, the judgment signal is fed back to the central control console, which confirms the vibration and issues an execution command to the vibration component 5 to complete the fixed-point vibration.

[0038] S6. After the concrete is vibrated by the side formwork vibrator 207 of the vibrating assembly 5 and the formwork assembly 2, wait for the concrete to set and then cure it. After curing, remove the formwork assembly 2 and the end formwork assembly 4 from the set concrete. The removed formwork assembly 2 and the end formwork assembly 4 can then be cleaned for the next use. In this step, the vibrating assembly 5 includes a vibrating transverse plate 501, a vibrating guide rail 502 on the vibrating transverse plate 501, a slidable transverse seat 504 on the vibrating guide rail 502, and a retractable vibrating rod 509 on the transverse seat 504. A transverse force 503 is provided on one side of the transverse moving plate 501. The transverse force 503 is used to make the vibrating assembly 5 move on the top beam guide rail 206. A transverse force 508 is provided on one side of the transverse moving seat 504. The transverse force 508 is used to drive the transverse moving seat 504 to move on the vibrating guide rail 502. Both the transverse force 503 and the transverse force 508 include a motor, a reducer and a drive wheel.

[0039] The transverse shift seat 504 is provided with a vibrating and collecting column 505. The vibrating and collecting column 505 is provided with a sliding cavity 511. The sliding cavity 511 is provided with multiple telescopic guide rods 510. The top of the vibrating and collecting column 505 is provided with a telescopic motor 506. The output shaft end of the telescopic motor 506 is provided with a telescopic lead screw 513. The sliding cavity 511 is also provided with a sliding telescopic guide seat 512. The telescopic guide seat 512 is slidably connected to the telescopic guide rod 510. The telescopic guide seat 512 is engaged with the telescopic screw rod 513. The telescopic screw rod 513 drives the telescopic guide seat 512 to slide up and down. A vibrating rod 509 is provided below the telescopic guide seat 512. The vibrating transverse plate 501 is also provided with a through groove 507. The vibrating rod 509 is telescopically and movable in the through groove 507.

[0040] After the concrete is vibrated to a dense state, it is cured using the existing automatic spraying process. The formwork assembly 2 and the end formwork assembly 4 are moved outward by power drive to demold, and remain in place without the need for hoisting. Manual assistance is used to complete the cleaning of the template, the cleaning of the platform, and the application of the release agent; after the end formwork component 4 is removed from the initial set concrete, a groove is reserved for placing the tensioning anchor plate 7.

[0041] S7. Insert the tension cable 9 inside the bellows 10 and install the tension anchor plate 7. Then use the tensioning assembly 3 to tension the tension cable 9 to the preset stress state. After tensioning is completed, cut off the excess tension cable 9. The tensioning jack 305 in the tensioning assembly 3 can be driven up and down by the lifting mechanism to precisely tension the tensioning cables 9 at different heights; the tensioning adopts the existing stress and elongation dual control process, and the excess tensioning cables 9 are cut off after the anchoring is qualified.

[0042] S8. After tensioning, grouting and sealing of the ducts are completed using existing technology. After the precast T-beams are lifted and detached after tensioning, steps S2-S8 are repeated to complete the cyclic fabrication of the T-beams. After the T-beams in this scheme are installed on the construction site, a post-cast groove (8) is formed at the joint end of the T-beams. The post-cast groove (8) is used to fill the joint with plastic concrete to reduce the later tension stress between the two T-beam segments.

[0043] The walking power unit 302 includes a motor, a reducer, drive wheels, and steering wheels.

[0044] After the precast T-beam is hoisted and moved away, the template assembly 2, the closing assembly 1, and the end formwork assembly 4 are reassembled and reset, quickly entering the next round of production, realizing continuous and efficient precasting.

[0045] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A method for manufacturing precast T-beams, characterized in that: The method includes: S1. Cast a precast platform (6) in the precast yard and install closing components (1) on both sides of the precast platform (6). S2. Install template component (2) on the closing component (1) and set detachable end mold components (4) at both ends of template component (2). S3. Connect the tensioning component (3) to the outside of the end formwork component (4). After the tensioning component (3) is installed, erect the T-beam reinforcement cage inside the formwork component (2). S4. A corrugated pipe (10) is installed through the steel cage of the T-beam, and the corrugated pipe (10) is connected to the end formwork assembly (4). S5. After completing the corrugated pipe (10) connection, pour concrete inside the template assembly (2). After the concrete is poured, install the vibrating assembly (5) on top of the template assembly (2). S6. After the concrete is vibrated using the vibrating assembly (5) and the formwork assembly (2), wait for the concrete to set and then cure it. After curing, remove the formwork assembly (2) and the end formwork assembly (4) from the set concrete. The removed formwork assembly (2) and the end formwork assembly (4) can then be cleaned for future use. S7. Insert the tension cable (9) inside the corrugated pipe (10) and install the tension anchor plate (7). Then use the tensioning assembly (3) to tension the tension cable (9) to the preset stress state. After tensioning is completed, cut off the excess tension cable (9). S8. After the precast T-beam is tensioned and detached, repeat steps S2-S8 to complete the cyclical production of the T-beam.

2. The method for manufacturing a precast T-beam according to claim 1, characterized in that: in step S1, the closing assembly (1) includes a closing guide rail (101), a sliding closing base plate (102) is provided on the closing guide rail (101), a closing power (103) is provided on the closing base plate (102), and a side formwork support (104) is also provided on one side of the closing base plate (102), the side formwork support (104) is used to support the bottom of the template assembly (2); The closing power (103) includes a motor, a reducer and a drive wheel, which is used to move on the closing guide rail (101).

3. The method for manufacturing a precast T-beam according to claim 2, characterized in that: In step S1, the precast platform (6) is precast using concrete. Tensioning positioning grooves (601) are provided at both ends of the precast platform (6). The tensioning positioning grooves (601) are used to connect the tensioning components (3). Step S1.1: Cast the precast platform (6) in the precast yard. Install steel pads at the top two corners of the precast platform (6) to avoid affecting the closing and sealing of the template assembly (2). When casting, a bottom template needs to be laid on the precast platform (6). Step S1.2: symmetrically arrange closing guide rails (101) on both sides of the precast platform (6) so that the closing base plate (102) can slide on the closing guide rails (101).

4. The method for manufacturing a precast T-beam according to claim 1, characterized in that: In step S2, the template assembly (2) includes a template support beam (201), a template column (202) is provided on one side of the template support beam (201), a side template (204) is provided on the other side, a side template vibrator (207) is provided on the outer wall of the side template (204), and a side template top plate (205) is provided on the top of the side template (204). The top of the template column (202) is provided with a template top beam (203), and the top of the template top beam (203) is provided with a top beam guide rail (206). The top beam guide rail (206) is used to install the vibrating assembly (5).

5. The method for manufacturing a precast T-beam according to claim 4, characterized in that: Step S2.1: Connect the template column (202) to the closing base plate (102), install the template support beam (201) on one side of the template column (202), and install the side template (204) on one side of the template support beam (201). Step S2.2: After the side template (204) is installed, start the closing power (103) to make the side template (204) fit against one side of the precast platform (6) and check the tightness of the fit between the side template (204) and the precast platform (6).

6. The method for manufacturing a precast T-beam according to claim 1, characterized in that: In step S3, the end mold assembly (4) includes an end mold main frame (401), an end mold top plate (402) is provided above the end mold main frame (401), a protruding plate (404) is provided on one side of the end mold main frame (401), an anchor plate guide hole (405) is provided on the protruding plate (404), and a detachable anchor plate guide cylinder (406) is provided in the anchor plate guide hole (405). The end mold top plate (402) is provided with symmetrical side end plate grooves (403). The end mold main frame (401) is provided with a threaded hole (407) on the outward side. The threaded hole (407) is used to connect with the tensioning component (3). The side end plate groove (403) is provided with a detachable side end baffle (208). The side end baffle (208) is in contact with the side mold top plate (205).

7. The method for manufacturing a precast T-beam according to claim 1, characterized in that: In step S3, the tensioning assembly (3) includes a tensioning base (301), a tensioning column (303) is provided above the tensioning base (301), a walking power source (302) is provided below the tensioning column (303), a tensioning connecting rod (304) is provided on one side of the tensioning column (303), and a through hole (311) is provided at the front end of the tensioning connecting rod (304), which is used to connect with the end mold assembly (4); The walking power (302) includes a motor, a reducer and a drive wheel. A lifting guide rail (308) is also provided between the tensioning connecting rods (304). A lifting slide (312) that can move up and down is provided between the lifting guide rails (308). A tensioning jack (305) is provided on the lifting slide (312). Above the tensioning connecting rod (304) is a lifting motor (306), and the output shaft end of the lifting motor (306) is provided with a lifting screw (309). The lifting screw (309) is meshed with the lifting slide (312), and the lifting screw (309) is used to drive the lifting slide (312) to move up and down. The tensioning jack (305) is also equipped with a coaxial detachable load-bearing cylinder (307) on one side.

8. A method for manufacturing a precast T-beam according to any one of claims 6-7, characterized in that: Step S3.1: Connect the threaded hole (407) of the end mold main frame (401) to the through hole (311) on the tensioning connecting rod (304) with bolts; Step S3.2, the construction personnel use automatic control of walking power (302) to move the tensioning component (3) carrying the end formwork main frame (401) to one end of the template component (2) and place the end formwork component (4) between the template components (2); Step S3.3, the tensioning component (3) adjusts its posture to move the end mold main frame (401) to the preset position of the end mold component (4) and then stops.

9. The method for manufacturing a precast T-beam according to claim 1, characterized in that: In steps S4-S8, the vibrating assembly (5) includes a vibrating transverse plate (501), a vibrating guide rail (502) is provided on the vibrating transverse plate (501), a slidable transverse seat (504) is provided on the vibrating guide rail (502), and a retractable vibrating rod (509) is provided on the transverse seat (504). A transverse force one (503) is provided on one side of the vibrating transverse plate (501). The transverse force one (503) is used to make the vibrating assembly (5) move on the top beam guide rail (206). A transverse force two (508) is provided on one side of the transverse seat (504). The transverse force two (508) is used to drive the transverse seat (504) to move on the vibrating guide rail (502). Both the transverse force one (503) and the transverse force two (508) include a motor, a reducer and a drive wheel.

10. The method for manufacturing a precast T-beam according to claim 1, characterized in that: The transverse seat (504) is provided with a vibrating and collecting column (505), the vibrating and collecting column (505) is provided with a sliding cavity (511), the sliding cavity (511) is provided with multiple telescopic guide rods (510), the top of the vibrating and collecting column (505) is provided with a telescopic motor (506), and the output shaft end of the telescopic motor (506) is provided with a telescopic screw (513). The sliding cavity (511) is also provided with a sliding telescopic guide seat (512). The telescopic guide seat (512) is slidably connected to the telescopic guide rod (510). The telescopic guide seat (512) is engaged with the telescopic screw rod (513). The telescopic screw rod (513) drives the telescopic guide seat (512) to slide up and down. A vibrating rod (509) is provided below the telescopic guide seat (512). A through groove (507) is also provided on the vibrating transverse plate (501). The vibrating rod (509) is telescopically and movable in the through groove (507). In step S6, after the end formwork assembly (4) is removed from the initial set concrete, a groove will be reserved for placing the tensioning anchor plate (7). In step S7, the tensioning jack (305) in the tensioning assembly (3) can move up and down to tension the tensioning cables (9) at different heights.

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