A prefabrication mold for subway assembly components

Abstract

This invention relates to the technical field of prefabrication of subway components, specifically to a prefabrication mold for subway prefabricated components. The casting template includes a side mold and a bottom mold. The bottom mold includes multiple interconnected unit plates, which are numbered sequentially along their arrangement direction. Multiple support beams correspond one-to-one with multiple unit plates, and multiple lifting mechanisms correspond one-to-one with multiple support beams. By using odd-even numbered unit plates in conjunction with corresponding support beams and lifting mechanisms, alternating segmented demolding operations are achieved. This changes the traditional one-time demolding mode of integral bottom molds. During the demolding process, the component always maintains a partially supported state, effectively avoiding cracking and warping deformation of prefabricated components due to suspension and instantaneous tension. This significantly improves the forming quality of subway prefabricated components and reduces the component scrap rate.

Description

Technical Field

[0001] This invention belongs to the technical field of subway component prefabrication, specifically relating to a prefabrication mold for subway prefabricated components. Background Technology

[0002] With the rapid development of urban rail transit construction, the prefabricated construction mode for subways has become the mainstream trend in subway engineering construction due to its advantages such as high construction efficiency, low on-site pollution, controllable component quality, and strong stability of construction period. Subway prefabricated components are mostly large slab and box-type structural components, which need to be standardized in the prefabrication plant for pouring, curing, and demolding before being transported to the construction site for assembly.

[0003] Currently, most existing subway component prefabrication molds adopt an integral bottom mold. When dismantling the bottom mold, it is necessary to lift and demold it as a whole or manually dismantle the surrounding templates. Due to the extreme weight of the bottom mold, large hoisting equipment is required for demolding. The operation process is complicated and demolding is difficult. In addition, manual demolding is labor-intensive and inefficient. The consistency of manual demolding is poor, which can easily lead to template deformation, uneven stress on the component during demolding, cracking, and warping, which seriously affects the forming accuracy of the component. Therefore, there is a need to provide an improved technical solution that addresses the shortcomings of the existing technology. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art. This invention provides a prefabrication mold for subway assembly components.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A prefabrication mold for subway assembly components includes: A casting template, comprising side molds and a bottom mold, wherein the bottom mold comprises multiple unit plates spliced ​​together, the multiple unit plates being arranged side by side and numbered sequentially along their arrangement direction; A pouring platform, the pouring platform comprising multiple parallel supporting beams, each of the multiple supporting beams corresponding one-to-one with a multiple unit plates; A lifting mechanism, wherein multiple lifting mechanisms correspond one-to-one with multiple support beams, to drive the support beams to move up and down longitudinally; The support beams are detachably fixed to the unit plates. Even-numbered support beams support the corresponding unit plates, while odd-numbered support beams descend to demold the unit plates. After demolding, the corresponding unit plates are removed. Odd-numbered support beams rise to support the corresponding unit panels, while even-numbered support beams descend to demold the unit panels. After demolding, the corresponding unit panels are removed.

[0006] Preferably, the edge of the unit board is provided with a tongue and groove joint, wherein the tongue and groove joint of the odd-numbered unit board is located at the lower edge, and the tongue and groove joint of the even-numbered unit board is located at the upper edge.

[0007] Preferably, the lifting mechanism includes no fewer than three lifting units evenly distributed along the length of the support beam. Each lifting unit includes a column and a lifting rod. The column is arranged longitudinally, and a lifting rod is provided inside the column. The piston rod of the lifting rod extends upward from the column and is connected to the support beam.

[0008] Preferably, the column is made of I-beam, and a lifting rod is provided on both sides of the web of the column. An end plate is provided on the upper end face of the column, and the end plate is provided with a through hole for the piston rod of the corresponding lifting rod.

[0009] Preferably, the support beam is made of I-beam, and drive wheels for corresponding unit plates are distributed on both sides of the support beam. The drive wheels are connected to the drive shaft of the power device to drive the unit plates to move along the length of the support beam.

[0010] Preferably, the drive wheel has a fan-shaped structure, and the radius of the fan-shaped drive wheel is greater than the vertical distance from the drive shaft axis to the upper surface of the support beam.

[0011] Preferably, the angle of the sector corresponding to the drive wheel is 180 degrees, and in the precast component casting state, the sector corresponding to the drive wheel points to the side away from the unit plate.

[0012] Preferably, the lifting mechanism is connected to a synchronous control system, which controls the odd-numbered support beams and even-numbered support beams to rise and fall alternately, and keeps the height of the support beams rising and falling in the same batch consistent.

[0013] Preferably, the side mold includes two long side plates arranged along the length direction of the bottom mold and two end side plates arranged along the width direction of the bottom mold, and the end side plates and the long side plates are detachably connected by a locking mechanism.

[0014] Beneficial effects: By using odd and even numbered unit plates in conjunction with corresponding support beams and lifting mechanisms, alternating segmented demolding operations are achieved, changing the traditional one-time demolding mode of integral bottom molds. During the demolding process, the components always maintain a local support state, effectively avoiding cracking and warping deformation of precast components due to suspension and instantaneous tension, greatly improving the molding quality of subway prefabricated components and reducing the component scrap rate.

[0015] The independent lifting mechanism corresponds one-to-one with the support beam, and together with the synchronous control system, multiple sets of support beams can be lifted and lowered synchronously and alternately with precision. Combined with the fan-shaped drive wheel structure on both sides of the support beam, the unit panel can be automatically lifted and slid out, which greatly reduces the intensity of manual labor, simplifies the demolding process, significantly improves the efficiency of component prefabrication production, and is suitable for continuous mass production on the assembly line. Attached Figure Description

[0016] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. Wherein: Figure 1 This is a simplified assembly diagram of the precast mold bottom mold and the pouring platform in a specific embodiment of the present invention; Figure 2 This is a structural diagram of the bottom mold of the prefabricated mold provided in a specific embodiment of the present invention; Figure 3 This is a schematic diagram showing the distribution of the support beams in a specific embodiment of the present invention; Figure 4 This is a schematic diagram of the drive wheel assembly in a specific embodiment of the present invention.

[0017] In the diagram: 1. Unit panel; 2. Support beam; 3. Column; 4. Lifting rod; 5. Drive wheel; 6. Overlapping tongue and groove joint. Detailed Implementation

[0018] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0019] In the description of this invention, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," and "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and do not require the invention to be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on the invention. The terms "connected" and "linked" used in this invention should be interpreted broadly. For example, they can refer to a fixed connection or a detachable connection; they can refer to a direct connection or an indirect connection through intermediate components. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0020] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0021] like Figures 1 to 4 As shown, a prefabricated mold for subway components includes a casting template, a casting platform, and a lifting mechanism. The casting template includes side molds and a bottom mold that cooperate with each other to form a closed casting cavity for the component. The bottom mold adopts a modular splicing structure, composed of multiple independent unit plates 1 spliced ​​together. These unit plates 1 are arranged side-by-side along the length or width of the mold, and all unit plates 1 are sequentially numbered along their arrangement direction, divided into odd-numbered unit plates 1 and even-numbered unit plates 1. This modular splicing design replaces the traditional integral bottom mold, enabling segmented and independent assembly and disassembly of the bottom mold, providing a structural basis for alternating demolding operations.

[0022] The pouring platform serves as the load-bearing support structure for the entire mold set, comprising multiple parallel support beams 2. These support beams 2 are configured one-to-one with multiple unit plates 1 of the bottom mold, and the unit plates 1 and support beams 2 are detachably fixed with bolts. Each support beam 2 independently corresponds to a unit plate 1, and can independently support the corresponding unit plate 1, ensuring that each unit plate 1 is subjected to independent forces and does not interfere with each other, thus avoiding the problems of force concentration and uneven deformation caused by the overall support.

[0023] Multiple lifting mechanisms are provided, each corresponding to a specific support beam 2. Each lifting mechanism independently drives its corresponding support beam 2 to lift vertically, enabling independent height adjustment of each support beam 2 and providing power support for segmented alternating demolding. The support beam 2 and its corresponding unit plate 1 adopt a detachable fixed connection structure, which can stably fix the unit plate 1 during the casting process, ensuring the integrity and flatness of the bottom mold structure. During demolding, the fixing can be quickly released, and the demolding operation can be completed in conjunction with the lifting of the support beam 2.

[0024] The alternating segmented demolding operation includes: even-numbered support beams 2 remain raised, supporting the corresponding numbered unit panels 1 to maintain their support position; odd-numbered support beams 2 are lowered in a controlled manner, causing the corresponding odd-numbered unit panels 1 to separate from the precast component and adjacent unit panels 1, completing the demolding operation of the odd-numbered unit panels 1; after demolding, the unit panels 1 corresponding to the odd-numbered numbers are removed; then, the odd-numbered support beams 2 rise back to their original position, supporting the precast component and maintaining its support state; even-numbered support beams 2 are lowered in a controlled manner, causing the even-numbered unit panels 1 to complete demolding separation, and then the even-numbered unit panels 1 are removed. By alternately demolding odd and even unit panels 1, step-by-step and segmented demolding can be achieved, avoiding the instantaneous tensile force generated by a one-time overall demolding on the precast component, effectively preventing component cracking and deformation.

[0025] In this embodiment, the bottom mold of the casting template is composed of five rectangular unit plates 1 arranged side by side. The five unit plates 1 are numbered 1-5 in sequence along the arrangement direction, where 1, 3, and 5 are odd-numbered unit plates 1, and 2 and 4 are even-numbered unit plates 1.

[0026] Odd-numbered unit plates 1 have an overlapping tongue-and-groove joint 6 along their lower edge, while even-numbered unit plates 1 have an overlapping tongue-and-groove joint 6 along their upper edge. Adjacent unit plates 1 are joined by staggered tongue-and-groove joints. This overlapping tongue-and-groove joint 6 structure ensures a tight seal and proper positioning between adjacent unit plates 1, guaranteeing a smooth bottom formwork surface and good sealing during pouring, preventing concrete leakage. Specifically, the overlapping tongue-and-groove joint 6 for odd-numbered unit plates 1 is located at the lower edge of the plate, while the overlapping tongue-and-groove joint 6 for even-numbered unit plates 1 is located at the upper edge of the plate, forming a staggered overlapping structure for odd and even unit plates 1. This staggered tongue-and-groove joint structure significantly improves the sealing performance of the joint, effectively preventing concrete slurry from leaking through the joint during pouring. Simultaneously, the staggered overlapping structure mutually restrains each other, improving the overall structural rigidity of the bottom formwork, preventing misalignment and bulging of unit plates 1 after pouring under pressure, and ensuring the flatness of the bottom surface of the component.

[0027] Furthermore, the side formwork includes two long side plates symmetrically arranged along the length of the bottom formwork, and two end side plates symmetrically arranged along the width of the bottom formwork. The four side plates enclose each other to form a rectangular frame structure, matching the molding requirements of prefabricated rectangular components for subways. The joints between the end side plates and the long side plates are detachably fixed using locking mechanisms. The locking mechanisms can adopt common locking structures such as bolt locking and snap-locking. During pouring, they are locked and fixed to ensure the stability of the side formwork frame structure and prevent deformation and bulging of the side plates due to concrete lateral pressure. They can be quickly unlocked during demolding, facilitating rapid disassembly of the side formwork and adapting to the overall prefabrication process.

[0028] In one optional embodiment, the lifting mechanism includes at least three lifting units evenly arranged along the length of the support beam 2. Multiple lifting units work synchronously to drive the lifting of a single support beam 2, ensuring the horizontality and stability of the support beam 2 during lifting. Each lifting unit includes a vertically arranged column 3 and a lifting rod 4. The column 3 is fixedly installed on the equipment foundation along the vertical direction, serving as a fixed support base. The column 3 integrates a lifting drive structure. The piston rod of the lifting rod 4 extends upwards through and beyond the top of the column 3, and the top piston rod of the lifting rod 4 is fixedly connected to the bottom of the support beam 2. By using lifting units evenly distributed at multiple points on the same support beam 2, tilting or deformation due to single-point stress can be avoided, ensuring the overall horizontal lifting of the support beam 2, and thus ensuring uniform stress distribution during demolding of the unit plate 1.

[0029] Furthermore, column 3 is made of I-beam steel, which can withstand the weight of the cast components and the self-weight of the mold for a long time without easily deforming. A lifting rod 4 is symmetrically arranged on both sides of the web of column 3, with each column 3 equipped with two lifting rods 4 for synchronous drive, further improving the load-bearing capacity and stability of the lifting support. At the same time, an end plate is fixedly installed on the upper surface of column 3, with through holes corresponding to the piston rods of the lifting rods 4. This guides and limits the extension and retraction of the lifting rods 4, preventing deviation or jamming during extension and retraction, and ensuring precise and smooth lifting movements.

[0030] In another optional embodiment, the support beam 2 is also made of I-beam steel. The I-beam support beam 2 is lightweight and has high structural strength, effectively supporting the weight of the unit plate 1 and the concrete components, and is not easily bent or deformed. Drive wheels 5 corresponding to the unit plate 1 are installed on both sides of the support beam 2. The drive wheels 5 are connected to the drive shaft of the power unit, which provides rotational power, driving the unit plate 1 to move horizontally along the length of the support beam 2. The power unit can be a stepper motor.

[0031] After demolding, the unit plate 1 can be moved horizontally by the drive wheel 5, which can quickly complete the disassembly, transfer and repositioning of the unit plate 1 without manual handling or large hoisting equipment, greatly improving the efficiency of demolding operation.

[0032] In this embodiment, the drive wheel 5 adopts a fan-shaped structure design, and the maximum radius of the fan-shaped drive wheel 5 is greater than the vertical distance between the drive shaft axis and the upper surface of the support beam 2. This structural design ensures that during the rotation of the fan-shaped drive wheel 5, the wheel body can effectively protrude from the upper surface of the support beam 2, forming effective contact support with the bottom surface of the unit plate 1. Through rotational friction, the unit plate 1 is driven to slide smoothly, so that after the unit plate 1 is removed, it can be slid out by the drive wheel 5. When there is no driving requirement, the drive wheel 5 is hidden on both sides of the support beam 2, without affecting the normal assembly of the unit plate 1.

[0033] Preferably, the center angle of the drive wheel 5 corresponding to the sector structure is set to 180 degrees, ensuring that the drive wheel 5 is a semi-circular sector structure with sufficient driving stroke. In the operation state of precast component casting, the arc surface of the sector drive wheel 5 points away from the unit plate 1, and the straight end face of the drive wheel 5 points towards the support beam 2, so as to avoid the drive wheel 5 bulging and pressing against the unit plate 1 during the casting process, causing uneven defects on the bottom surface of the component, and ensuring the forming quality of the component.

[0034] The drive wheel 5 is mounted on the web of the support beam 2 via a horizontally extending drive shaft. To ensure the driving effect, there are no fewer than three drive wheels 5 on both sides of the support beam 2. The drive wheels 5 on the same support beam 2 can be driven synchronously through a transmission chain.

[0035] Furthermore, this application includes a synchronous control system that controls the lifting mechanisms and precisely regulates the operating status of all lifting mechanisms. The synchronous control system enables alternating lifting control of odd-numbered and even-numbered support beams 2, precisely switching between the two demolding modes. Simultaneously, it strictly controls the lifting stroke of support beams 2 in the same batch, ensuring that the lifting height of support beams 2 in the same batch is completely consistent. This eliminates problems such as tilting of unit plates 1 and uneven stress on components caused by height differences, further improving demolding accuracy and stability.

[0036] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention shall be within the scope of protection of the pending claims of the present invention.

Claims

1. A subway fabricated component prefabricated mold, characterized by, include: A casting template, comprising side molds and a bottom mold, wherein the bottom mold comprises multiple unit plates spliced ​​together, the multiple unit plates being arranged side by side and numbered sequentially along their arrangement direction; A pouring platform, the pouring platform comprising multiple parallel supporting beams, each of the multiple supporting beams corresponding one-to-one with a multiple unit plates; A lifting mechanism, wherein multiple lifting mechanisms correspond one-to-one with multiple support beams, to drive the support beams to move up and down longitudinally; The support beams are detachably fixed to the unit plates. Even-numbered support beams support the corresponding unit plates, while odd-numbered support beams descend to demold the unit plates. After demolding, the corresponding unit plates are removed. Odd-numbered support beams rise to support the precast components, while even-numbered support beams descend to demold the unit panels. After demolding, the corresponding unit panels are removed. The edges of the unit panels are provided with tongue and groove joints, wherein the tongue and groove joints of the odd-numbered unit panels are located at the lower edge, and the tongue and groove joints of the even-numbered unit panels are located at the upper edge. The support beam is made of I-beams, and drive wheels for corresponding unit plates are distributed on both sides of the support beam. The drive wheels are connected to the drive shaft of the power unit to drive the unit plates to move along the length of the support beam. The drive wheels have a fan-shaped structure, and the radius of the fan-shaped drive wheel is greater than the vertical distance from the axis of the drive shaft to the upper surface of the support beam.

2. The subway fabricated component prefabricated mold according to claim 1, characterized in that, The lifting mechanism includes no fewer than three lifting units evenly distributed along the length of the support beam. Each lifting unit includes a column and a lifting rod. The column is arranged longitudinally, and a lifting rod is provided inside the column. The piston rod of the lifting rod extends upward from the column and is connected to the support beam.

3. The subway fabricated component prefabricated mold according to claim 2, characterized in that, The column is made of I-beams, and a lifting rod is provided on both sides of the web of the column. An end plate is provided on the upper end face of the column, and the end plate is provided with a through hole for the piston rod of the corresponding lifting rod.

4. The prefabrication mold for subway prefabricated components according to claim 1, characterized in that, The angle of the sector corresponding to the drive wheel is 180 degrees. When the precast component is in the casting state, the sector corresponding to the drive wheel points to the side away from the unit plate.

5. The prefabrication mold for subway prefabricated components according to claim 1, characterized in that, The lifting mechanism is connected to a synchronous control system, which controls the odd-numbered support beams to rise and fall alternately with the even-numbered support beams, and keeps the height of the support beams rising and falling in the same batch consistent.

6. The prefabrication mold for subway prefabricated components according to claim 1, characterized in that, The side mold includes two long side plates arranged along the length of the bottom mold and two end side plates arranged along the width of the bottom mold. The end side plates and the long side plates are detachably connected by a locking mechanism.

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