A suspended culvert wall integral formwork trolley

Abstract

This invention relates to the field of culvert construction and discloses a suspended culvert wall integral formwork trolley, including a track and a formwork trolley body. The formwork trolley body includes a rigid truss frame, an integral formwork, and an automatic compensation and adjustment mechanism. The integral formwork is connected to the rigid truss frame through the automatic compensation and adjustment mechanism, which includes a control unit and a hydraulic drive unit. The hydraulic drive unit is connected to a bracket, and a temperature sensor is embedded in the side of the end of each support rod. The temperature sensor is used to control the extension and retraction of the hydraulic drive mechanism according to the temperature change of the formwork to compensate for thermal deformation errors. This design solves the problem of dimensional deviations caused by deformation of large-volume steel structure formwork under extreme temperature difference environments by introducing real-time temperature monitoring and an active error compensation mechanism. The sensor is embedded in the side of the support rod and in direct contact with the metal groove of the formwork, eliminating temperature measurement lag.

Description

Technical Field

[0001] This invention relates to the field of culvert construction, and in particular to a suspended culvert wall integral formwork trolley. Background Technology

[0002] Currently, culvert wall construction commonly utilizes formwork trolleys for pouring concrete. Existing formwork trolley technologies, such as common suspended or self-propelled trolleys, typically include a track system, a rigid truss frame, integral formwork, and a hydraulic support and positioning system. Through track guidance and hydraulic jacking, the movement, positioning, and demolding of the formwork are achieved, significantly improving construction efficiency and reducing grout leakage at joints compared to traditional piecework formwork processes.

[0003] However, with the increasing demands on concrete forming quality in engineering construction, especially the high standards required for wall dimensional accuracy (such as thickness and verticality), the existing technology has revealed the following shortcomings in adaptability to complex environments: The existing trolley frames, formwork, and tracks are mostly made of steel, which has the physical property of thermal expansion and contraction. In scenarios with large diurnal temperature differences or seasonal construction, such as the hot and rainy summers and cold and damp winters in southern regions, the structural components will undergo significant thermal deformation. For example, the theoretical deformation of a 10-meter-long steel component under a 20°C temperature difference can reach 2.4mm, exceeding the allowable error range for high-precision construction. Existing technologies mostly rely on manual visual inspection or static mechanical positioning, lacking real-time monitoring and automatic compensation adjustment mechanisms for temperature changes. This results in poor dimensional consistency of culvert walls poured under different temperature conditions, easily leading to misalignment or dimensional deviations.

[0004] Therefore, developing a suspended culvert wall integral formwork trolley that can monitor the temperature of the formwork body in real time, automatically compensate for thermal deformation errors, and is easy to maintain has become an urgent problem to be solved in the current technical field. Summary of the Invention

[0005] The purpose of this invention is to provide a suspended culvert wall integral formwork trolley to solve the above problems. The specific technical solution is as follows: A suspended culvert wall integral formwork trolley includes a track and a formwork trolley body. The track includes steel rails laid parallel to the culvert. The formwork trolley body includes a rigid truss frame, an integral formwork, and an automatic compensation and adjustment mechanism. A traveling mechanism is provided at the bottom of the rigid truss frame, and the traveling mechanism is slidably connected to the steel rails. The integral formwork is connected to the rigid truss frame through the automatic compensation and adjustment mechanism, and the integral formwork is installed on both sides of the rigid truss frame through a sliding insertion mechanism. The automatic compensation and adjustment mechanism includes a control unit and a hydraulic drive unit. The hydraulic drive unit is connected to the integral formwork and is used to drive the formwork to move. The hydraulic drive unit is connected to a bracket, and the bracket has multiple support rods. The integral formwork has a groove for receiving the support rods. A temperature sensor is embedded on the side of the end of each support rod. The control unit is electrically connected to the temperature sensor and the hydraulic drive mechanism respectively. The support rod entering the groove has only its side in contact with the groove. The temperature sensor is used to control the extension and contraction of the hydraulic drive mechanism according to the temperature change of the formwork to compensate for thermal deformation error.

[0006] As an improvement to the above technical solution, the rail has multiple sets of positioning holes, and the bottom of the traveling mechanism is provided with a track positioning pin, which is adapted to the positioning hole; the positioning hole is an elongated hole extending along the length of the rail; the width of the elongated hole and the diameter of the track positioning pin are in clearance fit; the length of the elongated hole is 2-3 mm greater than the diameter of the track positioning pin.

[0007] As an improvement to the above technical solution, the hydraulic drive unit is a telescopic rod, and a quick connector is provided between the telescopic rod and the integral template for detachable connection; the hydraulic drive unit also includes a servo proportional valve for controlling the extension amount and extension speed of the telescopic rod.

[0008] As one of the improvements to the above technical solution, the control unit pre-stores the linear expansion coefficient parameter α of steel and the reference temperature value T. The control unit is configured to execute the following compensation logic: Real-time temperature sensor data Tcurrent is collected, and the current temperature difference ΔT is calculated: ΔT = Tcurrent - Treference. The theoretical thermal deformation ΔL is calculated based on the coefficient of linear expansion of steel α and the characteristic dimension L0 of the template: Calculate according to the formula ΔL = L0×α×ΔT; The hydraulic drive unit is controlled to move the integral template by a distance equal to the theoretical thermal deformation ΔL, in the opposite direction to the thermal expansion direction.

[0009] As an improvement to the above technical solution, the detection end of the temperature sensor embedded in the support rod is flush with the side of the support rod.

[0010] As an improvement to the above technical solution, a gap is provided between the end face of the support rod and the bottom surface of the groove.

[0011] As an improvement to the above technical solution, the traveling mechanism includes a traveling beam and a traveling wheel set. The traveling beam is connected to the rigid truss frame, and the traveling wheel set is rotatably connected to the rigid truss frame. The traveling wheel set rolls with the rail.

[0012] As an improvement to the above technical solution, the bracket is provided with four support rods, which are respectively set at the corners of the integral template.

[0013] The beneficial effects of this invention are as follows: This design solves the problem of dimensional deviations caused by deformation of large-volume steel structure formwork under extreme temperature differences by introducing real-time temperature monitoring and an active error compensation mechanism. By monitoring the formwork body temperature in real time with sensors and using formulas for displacement compensation, millimeter-level errors caused by thermal expansion and contraction are reduced to a minimum, ensuring the consistency of wall thickness and verticality. The rail positioning holes adopt an elongated oval design, ensuring both lateral positioning accuracy and allowing for longitudinal free expansion and contraction of the rails, preventing the rails from arching due to heat. Compared to pieced-together formwork, the integral formwork reduces the number of seams, fundamentally solving the persistent problems of grout leakage, misalignment, and poor surface flatness. The sensor is embedded in the side of the support rod and in direct contact with the metal of the formwork groove, measuring the temperature of the formwork body rather than the ambient temperature, eliminating temperature measurement lag. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the structure of the present invention.

[0016] Figure 2 This is a schematic diagram of the automatic replenishment and adjustment mechanism of the present invention.

[0017] Figure 3 This is a schematic diagram of the positioning hole of the present invention.

[0018] In the diagram: 1. Track; 2. Template vehicle body; 3. Walking mechanism; 4. Multi-point support; 5. Temperature sensor; 11. Positioning hole; 21. Rigid truss frame; 22. Integral template; 221. Groove; 23. Automatic replenishment and adjustment mechanism; 231. Hydraulic drive unit; 232. Control unit. Detailed Implementation

[0019] The technical solutions in the embodiments of the present invention will be clearly and completely described below. 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.

[0020] Please see Figures 1-3 The system comprises two main parts: track 1 and the formwork vehicle body 2. Track 1 consists of steel rails laid parallel to both sides of the culvert foundation, extending along the culvert's axis and fixed to the culvert foundation concrete by embedded parts or pressure plates. The steel rails serve as a guiding structure for the formwork vehicle, providing a directional trajectory and preventing lateral deviations during movement. Heavy-duty steel rails, preferably QU80 or QU100, are preferred to ensure load-bearing capacity and wear resistance.

[0021] The main body 2 of the template vehicle includes a rigid truss frame 21, an integral template 22, and an automatic replenishment and adjustment mechanism 23.

[0022] The rigid truss frame 21 is a frame structure welded from steel sections to fit the culvert cross-section, bearing construction loads and serving as the mounting carrier for various components. The rigid structure of the frame ensures the overall stability of the equipment and can withstand the lateral pressure and construction loads generated during concrete pouring.

[0023] The traveling mechanism 3 is located at the bottom of the rigid truss frame 21 and is slidably connected to the rails. Specifically, the traveling mechanism 3 includes a traveling beam and a traveling wheel set. The traveling beam is laterally connected to the bottom of the rigid truss frame 21, and the traveling wheel set is rotatably connected to both ends of the traveling beam. The traveling wheel set rolls along the rails, enabling convenient movement of the formwork vehicle and replacing manual handling of the formwork.

[0024] Integrated template 22 installation structure: The integral formwork 22 is a large steel formwork structure that perfectly matches the outline of the culvert wall. The integral formwork 22 is installed on both sides of the rigid truss frame 21 through a sliding plug-in mechanism, achieving a detachable connection.

[0025] The sliding connection mechanism includes a horizontal guide rail mounted on the rigid truss frame 21 and a slider mounted on the back of the integral template 22. The slider slides in conjunction with the horizontal guide rail, allowing the template to be moved laterally along the guide rail to adjust its position. The sliding connection mechanism also includes a quick-locking pin, which is used to lock the relative position of the template and the frame after the template position is adjusted, ensuring that the template does not shift during the pouring process.

[0026] This installation method eliminates the need for segmented assembly and disassembly, while reducing seams to avoid grout leakage and misalignment, significantly improving the flatness and verticality of the wall structure.

[0027] Automatic replenishment and adjustment mechanism 23: The automatic adjustment mechanism 23 includes a control unit 232 and a hydraulic drive unit 231, used to achieve automatic temperature compensation adjustment of the template position. The hydraulic drive unit 231 is a telescopic rod, which is connected to the integral template 22 and used to drive the template movement. A quick-connect coupling is provided between the telescopic rod and the integral template 22 for detachable connection, facilitating template disassembly, replacement, and maintenance. The hydraulic drive unit 231 also includes a servo proportional valve for controlling the extension amount and speed of the telescopic rod, ensuring the accuracy of template positioning.

[0028] The hydraulic drive unit 231 is connected to a bracket, which has multiple support rods. In this embodiment, the bracket has four support rods, which are respectively positioned at the corners of the integral template 22.

[0029] Groove 221 mating structure with support rod: The integral template 22 is provided with a groove 221 for receiving the support rod. It should be noted that only one side of the support rod entering the groove 221 contacts the groove 221. A gap is provided between the end face of the support rod and the bottom surface of the groove 221. A temperature sensor 5 is embedded in the end side of each support rod. The detection end of the temperature sensor 5 embedded in the support rod is flush with the side of the support rod.

[0030] When the support rod is inserted into the groove 221, the detection end of the temperature sensor 5 contacts the inner wall of the groove 221. Due to the direct metal-to-metal contact, the temperature sensor 5 can accurately collect the real-time temperature of the template body, rather than the ambient temperature, eliminating temperature measurement lag error. When the multi-point bracket 4 is inserted into the receiving groove, the scraping structure generates sliding friction with the inner wall of the receiving groove, automatically scraping off the dust, concrete slurry, or oxide layer attached to the inner wall surface, ensuring the acquisition accuracy of the temperature sensor 5. It is understandable that the bottom surface of the receiving groove is prone to dust accumulation, and as the multi-point bracket 4 is inserted, dust tends to accumulate on the inner bottom surface of the receiving groove, which will affect the operation of the temperature sensor 5 to some extent. Therefore, this design is taken into account in the construction scenario.

[0031] Control unit 232 and compensation logic: The control unit 232 is electrically connected to the temperature sensor 5 and the hydraulic drive mechanism, respectively. The control unit 232 has pre-stored the linear expansion coefficient parameter α of the steel and the reference temperature value T. 基准 .

[0032] The control unit 232 is configured to execute the following compensation logic: Real-time acquisition of 5T temperature sensor data 当前 Calculate the current temperature difference ΔT, ΔT = T 当前 -T 基准 ; The theoretical thermal deformation ΔL is calculated based on the coefficient of linear expansion of steel α and the characteristic dimension L0 of the template, and is calculated according to the formula ΔL = L0 × α × ΔT. The hydraulic drive unit 231 is controlled to move the integral template 22 by a distance equal to the theoretical thermal deformation ΔL, in the opposite direction to the thermal expansion direction.

[0033] As a preferred embodiment, the rail has multiple sets of positioning holes 11 pre-set, and the bottom of the traveling mechanism 3 is provided with a rail positioning pin. The rail positioning pin is adapted to the positioning hole 11, and the positioning hole 11 is an elongated hole extending along the length of the rail 1. The width of the elongated hole and the diameter of the rail positioning pin are in clearance fit, with a clearance ≤ 0.2 mm. The length of the elongated hole is 2-3 mm greater than the diameter of the rail positioning pin. The clearance between the width of the elongated hole and the diameter of the positioning pin is ≤ 0.2 mm to ensure the lateral positioning accuracy of the trolley and ensure the accuracy of the wall thickness. The length of the elongated hole is 2-3 mm greater than the diameter of the positioning pin to reserve space for the longitudinal expansion and contraction of the rail due to temperature changes, and to prevent the rail 1 from warping due to heat.

[0034] As a further optimization, the positioning pin of the track 1 can be a tapered pin, or it can be equipped with an eccentric locking device to eliminate longitudinal gaps and lock the position after being inserted into the elongated hole, so as to ensure the final positioning accuracy.

[0035] Working principle: During construction, track 1 is first laid along the culvert construction direction, and the formwork trolley is placed on track 1 via its wheel set. After pushing or pulling the formwork trolley to the section to be constructed, the positioning pin of track 1 is inserted into the positioning hole 11 of track 1 to achieve precise longitudinal positioning.

[0036] The automatic adjustment mechanism 23 is activated, the temperature sensor 5 collects the temperature of the template body, the control unit 232 calculates the thermal deformation compensation, and the hydraulic drive unit 231 drives the integral template 22 to move along the sliding insertion mechanism to the compensation position. After completion, the template position is locked by the quick-locking pin, forming a closed wall pouring cavity for concrete pouring.

[0037] After the pouring is completed, the hydraulic drive unit 231 retracts, causing the integral formwork 22 to detach from the wall and complete the demolding. After the locking pin is released and the positioning pin is pulled out, the formwork trolley can be moved along the track 1 to the next construction position to repeat the operation.

[0038] During the pouring process, the system continuously monitors the temperature and position of the formwork. If abnormal displacement (such as bulging) is detected, the hydraulic drive unit 231 is automatically adjusted to compensate. After the concrete pouring is completed, once the concrete strength reaches more than 75% of the design strength, the hydraulic drive unit 231 retracts, causing the integral formwork 22 to detach from the wall and complete the demolding. The locking pin is then released and the positioning pin is pulled out, allowing the formwork trolley to move along track 1 to the next construction position for repeated operation.

[0039] The temperature of the template body is monitored in real time by the contact temperature sensor 5, eliminating the interference of ambient temperature and temperature measurement lag. The control unit 232 automatically calculates and executes compensation actions to eliminate the influence of temperature deformation on positioning accuracy. The template position deviation can be controlled within 2mm, which is far better than the existing technical deviation standard (generally 5-10mm).

Claims

1. A suspended culvert wall integral formwork trolley, characterized in that, The system includes a track and a template vehicle body. The track consists of steel rails laid parallel to the culvert. The template vehicle body includes a rigid truss frame, an integral template, and an automatic compensation and adjustment mechanism. The bottom of the rigid truss frame is equipped with a traveling mechanism, which is slidably connected to the steel rails. The integral template is connected to the rigid truss frame via the automatic compensation and adjustment mechanism and is installed on both sides of the rigid truss frame via a sliding insertion mechanism. The automatic compensation and adjustment mechanism includes a control unit and a hydraulic drive unit. The hydraulic drive unit is connected to the integral template and is used to drive the template to move. The hydraulic drive unit is connected to a bracket, which has multiple support rods. The integral template has grooves for receiving the support rods. A temperature sensor is embedded in the side of the end of each support rod. The control unit is electrically connected to the temperature sensor and the hydraulic drive mechanism respectively. The support rod entering the groove has only its side in contact with the groove. The temperature sensor is used to control the extension and retraction of the hydraulic drive mechanism according to the temperature change of the template to compensate for thermal deformation errors.

2. The suspended culvert wall integral formwork trolley according to claim 1, characterized in that: The rail has multiple pre-set positioning holes, and the bottom of the traveling mechanism is provided with a rail positioning pin, which is adapted to the positioning holes. The positioning hole is an elongated hole extending along the length of the rail. The width of the elongated hole and the diameter of the rail positioning pin are in clearance fit. The length of the elongated hole is 2-3 mm greater than the diameter of the rail positioning pin.

3. The suspended culvert wall integral formwork trolley according to claim 2, characterized in that: The hydraulic drive unit is a telescopic rod, and a quick connector is provided between the telescopic rod and the integral template for detachable connection; the hydraulic drive unit also includes a servo proportional valve for controlling the extension amount and extension speed of the telescopic rod.

4. The suspended culvert wall integral formwork trolley according to claim 3, characterized in that: The control unit contains pre-stored parameters for the linear expansion coefficient α of steel and a reference temperature value T. 基准 ; The control unit is configured to execute the following compensation logic: Real-time acquisition of temperature sensor data T 当前 Calculate the current temperature difference ΔT, ΔT = T 当前- T 基准 ; The theoretical thermal deformation ΔL is calculated based on the coefficient of linear expansion of steel α and the characteristic dimension L0 of the template: Calculate according to the formula ΔL = L0×α×ΔT; The hydraulic drive unit is controlled to move the integral template by a distance equal to the theoretical thermal deformation ΔL, in the opposite direction to the thermal expansion direction.

5. A suspended culvert wall integral formwork trolley according to claim 1, characterized in that: The detection end of the temperature sensor, which is embedded in the support rod, is flush with the side of the support rod.

6. The suspended culvert wall integral formwork trolley according to claim 1, characterized in that: A gap is provided between the end face of the support rod and the bottom surface of the groove.

7. The suspended culvert wall integral formwork trolley according to claim 1, characterized in that: The traveling mechanism includes a traveling beam and a traveling wheel set. The traveling beam is connected to the rigid truss frame, and the traveling wheel set is rotatably connected to the rigid truss frame. The traveling wheel set rolls in cooperation with the rail.

8. A suspended culvert wall integral formwork trolley according to claim 1, characterized in that: The support frame has four support rods, which are respectively set at the corners of the integral template.

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