An automatic production system for prefabricated small box girder

Abstract

The application relates to the technical field of small box girder production, and discloses an automatic production system for prefabricated small box girders, a production unit is used for the production work of the prefabricated small box girders, a positioning unit is used for the mold positioning work during production of the production unit, a collection unit is used for collecting data during mold production, a management unit is used for production work management, and a quality inspection unit is used for detecting the size data of the prefabricated small box girders after production; the application realizes continuous and beat production of the prefabricated small box girders by combining a movable side mold with a flow line operation mode, the opening and closing, positioning and circulation process of the side mold can be automatically carried out, auxiliary operation time is reduced, mold precision and stability are improved, manual intervention is reduced, the consistency of the prefabricated small box girder size is ensured, subsequent installation difficulty and quality risk are reduced, intelligent evaluation and dynamic response of multi-parameter coupling risk can early warn abnormal working conditions and prevent quality defects.

Description

Technical Field

[0001] This invention relates to the field of small box girder production technology, and more specifically to an automated production system for prefabricated small box girders. Background Technology

[0002] Bridge construction, as a crucial component of transportation infrastructure, is experiencing rapid development. Precast small box girders, a common form of bridge superstructure, are widely used in bridge engineering due to their advantages such as fast construction speed, easy quality control, and minimal impact on traffic. These girders are applied in various scenarios, including highways, urban viaducts, and railway bridges, and their demand continues to increase. Small box girders, as the core superstructure of bridge engineering, are widely used in highways, urban elevated roads, and railway bridges. Currently, the industry generally adopts the fixed side formwork combined with fixed platform method for production. The basic process of this method is as follows: the bottom formwork and side formwork are installed on the fixed platform, and the finished product is obtained after manual binding of steel bars, pouring of concrete, curing, and demolding. Although this technology is relatively mature, the following prominent problems exist in practical applications: Traditional precast small box girder production often uses fixed side molds. The installation and dismantling of the molds require a large amount of manual operation. After each production run, the molds need to be repositioned and adjusted, which consumes a lot of time and manpower, making it difficult to improve production efficiency and meet the schedule requirements of large-scale engineering projects. In the production of traditional precast small box girders, the side mold closing relies on manual operation, resulting in low positioning accuracy, large deviations, and a lack of effective automatic locking mechanisms. This leads to poor box girder dimensional consistency, installation difficulties, and affects structural safety and durability. Traditional production lacks real-time monitoring and comprehensive judgment capabilities, making it difficult to detect abnormal conditions in time. This can easily lead to box girder deformation, uneven vibration, or mold damage, and it is also difficult to trace the source of problems in the processing stage. Summary of the Invention

[0003] In order to overcome the above-mentioned defects of the prior art, the embodiments of the present invention provide an automated production system for prefabricated small box girders to solve the technical problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: an automated production system for precast small box girders, comprising a production unit, a positioning unit, a data acquisition unit, a management unit, and a quality inspection unit. The production unit is used for the production of precast small box girders, the positioning unit is used for mold positioning during production, the data acquisition unit is used to acquire data during mold production, the management unit is used for production management, and the quality inspection unit is used to inspect the dimensional data of the precast small box girders after production. The production unit includes a track module, a side mold module, and a workstation module. The track module is a parallel and continuous track arranged longitudinally along the production workshop. The track includes a conveying track for production and a return track for resetting. The side mold module is slidably installed on the track module. Each side mold module includes a bottom mold platform and two side molds arranged opposite each other. The workstation modules are arranged sequentially along the track module and include a steel reinforcement cage placement workstation, a concrete pouring workstation, a steam curing workstation, and a demolding and finishing workstation.

[0005] In a preferred embodiment, the production unit performs the following steps: Step S1: Hoist the tied steel reinforcement cage into the side formwork module of the steel reinforcement cage placement station, and the two side formworks in the side formwork module close together in the middle. Step S2: The side formwork module automatically travels along the conveying track inside the track module to the concrete pouring position, pours the concrete into the formwork, and the attached vibrator automatically starts at the same time. Step S3: After the pouring is completed, the side formwork module continues to move to the steam curing station to cure the box girder; Step S4: After the curing is completed, the side mold module is moved to the demolding and repair station. The side mold module opens automatically, and after demolding and repair, it is transported out. Step S5: The empty side formwork module returns to the steel reinforcement cage placement station via the turnover track to start the next production cycle.

[0006] In a preferred embodiment, the positioning unit includes a coarse positioning module and a fine positioning module. The coarse positioning module drives the two side molds of the side mold module to move to the mold closing position 5-10mm by hydraulic drive and then stops. The coarse positioning module controls the hydraulic pressure to be in a pressure-holding state.

[0007] In a preferred embodiment, the precision positioning module controls the two side molds to move again, and the precision positioning module provides position feedback with a resolution of 0.01mm through a displacement sensor. When the two side molds reach their respective target positions and the left and right deviations are within 0.2mm, the mold closing operation is completed. When the positioning unit completes the mold closing operation, it automatically performs mechanical locking to fix the positions of the two side molds.

[0008] In a preferred embodiment, the acquisition unit collects displacement data WL, vibration frequency data ZD, and pressure data YL on the side formwork surface when the side formwork module is working at the concrete pouring position, and sends them to the management unit. The management unit receives the data collected by the acquisition unit and calculates a judgment value P. The formula for calculating the judgment value P is as follows: In the formula, k1, k2 and k3 are all weighting coefficients, BZ1 is the standard safe displacement data, BZ2 is the standard safe vibration frequency data, and BZ3 is the standard safe pressure data.

[0009] In a preferred embodiment, when selecting the weight coefficients k1, k2, and k3 within the management unit, a standardized regression coefficient method based on multiple linear regression is used. A regression model is established by combining displacement data, vibration frequency data, pressure data on the side mold surface, and defect indicators of side mold movement. All variables are standardized so that the absolute value of each regression coefficient directly reflects the degree of influence of each factor changing by one standard deviation on the quality defect. This absolute value is used as the original contribution of each factor, and coefficients k1, k2, and k3 are obtained through normalization.

[0010] In a preferred embodiment, the management unit compares the calculated judgment value P with its internal lower safety threshold Y1 and upper safety threshold Y2. When the judgment value P < the lower safety threshold Y1, the management unit continues production. When the lower safety threshold Y1 ≤ the judgment value P < the upper safety threshold Y2, the management unit issues an early warning. When the upper safety threshold Y2 ≤ the judgment value P, the management unit suspends production.

[0011] In a preferred embodiment, the quality inspection unit detects the dimensional data of the small box girder after production. The dimensional data includes beam width error (KW), beam height error (GW), camber (GD), and surface roughness (CC). The quality inspection unit analyzes the dimensional data. When any one or both of the beam width error (KW) and beam height error (GW) exceed their corresponding standard values, the quality inspection unit sends a positioning command to the management unit. When the camber (GD) exceeds the standard camber value, the quality inspection unit sends a pouring command to the management unit. When the surface roughness (CC) exceeds the standard surface roughness value, the quality inspection unit sends a curing command to the management unit.

[0012] In a preferred embodiment, when the dimensional data detected by the quality inspection unit does not exceed its corresponding standard value, the quality inspection unit does not send an instruction and remains in standby mode. When the management unit receives a positioning instruction, it warns of a problem with the positioning process. When the management unit receives a pouring instruction, it warns of a problem with the pouring process. When the management unit receives a curing instruction, it warns of a problem with the curing process.

[0013] The technical effects and advantages of this invention are as follows: 1. This invention combines mobile side molds with assembly line operation mode to achieve continuous and rhythmic production of precast small box girders. The opening, closing, positioning and transfer of side molds can be automated, reducing auxiliary operation time. 2. This invention uses a combination of hydraulic drive and displacement sensors, with a coarse positioning module and a fine positioning module within the positioning unit, to achieve automatic mold closing to a left-right deviation of ≤0.2mm. After mold closing, it automatically performs mechanical locking, thereby improving mold closing accuracy and stability, reducing manual intervention, ensuring the consistency of precast small box girder dimensions, and reducing subsequent installation difficulty and quality risks. 3. This invention acquires displacement, vibration frequency, and pressure data in real time through the acquisition unit, and the management unit calculates the judgment value P. Combined with the lower safety threshold 1Y and the upper safety threshold Y2, it performs graded early warning and intervention, realizing intelligent assessment and dynamic response of multi-parameter coupled risks. It can provide early warning of abnormal working conditions, prevent quality defects, ensure the safety and controllability of the production process, and the quality inspection unit automatically sends instructions to trace the process that caused the problem, avoid the recurrence of the problem, and thus improve the quality of small box girders. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the overall system composition of the present invention. Detailed Implementation

[0015] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. In addition, the forms of the various structures described in the following embodiments are merely illustrative. The automated production system for prefabricated small box girders involved in the present invention is not limited to the structures described in the following embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] Reference Figure 1 This invention provides an automated production system for precast small box girders, including a production unit, a positioning unit, a data acquisition unit, a management unit, and a quality inspection unit. The production unit is used for the production of precast small box girders, the positioning unit is used for mold positioning during production, the data acquisition unit is used to collect data during mold production, the management unit is used for production management, and the quality inspection unit is used to inspect the dimensional data of the precast small box girders after production.

[0017] In this embodiment, by integrating five major units—production, positioning, data acquisition, management, and quality inspection—and adopting a dual-track (conveying track + turnover track) assembly line layout and multi-station setup, this application achieves fully automated and continuous production of precast small box girders from the insertion of the steel reinforcement skeleton into the mold to demolding and finishing. This significantly improves production efficiency, shortens the production cycle, and meets the schedule requirements of large-scale engineering construction.

[0018] Reference Figure 1The production unit includes a track module, a side mold module, and a workstation module. The track module is a parallel and continuous track arranged longitudinally along the production workshop. The track includes a conveying track for production and a return track for resetting. The side mold module is slidably installed on the track module. Each side mold module includes a bottom mold platform and two side molds arranged opposite each other. The workstation modules are arranged sequentially along the track module and include a steel reinforcement cage placement workstation, a concrete pouring workstation, a steam curing workstation, and a demolding and finishing workstation.

[0019] In this embodiment, when the production unit is automating the production of precast small box girders, the track module provides a moving track, enabling it to automate production and resetting operations. The side mold module automatically performs mold closing operations, and the four workstations of the workstation module are arranged sequentially on the track, thereby achieving automated full-cycle production without wasting a large amount of manual labor and improving the level of intelligent production.

[0020] Reference Figure 1 The production unit performs the following steps: Step S1: Hoist the tied steel reinforcement cage into the side formwork module of the steel reinforcement cage placement station, and the two side formworks in the side formwork module close together in the middle. Step S2: The side formwork module automatically travels along the conveying track inside the track module to the concrete pouring position, pours the concrete into the formwork, and the attached vibrator automatically starts at the same time. Step S3: After the pouring is completed, the side formwork module continues to move to the steam curing station to cure the box girder; Step S4: After the curing is completed, the side mold module is moved to the demolding and repair station. The side mold module opens automatically, and after demolding and repair, it is transported out. Step S5: The empty side formwork module returns to the steel reinforcement cage placement station via the turnover track to start the next production cycle.

[0021] In this embodiment, the above production steps enable automatic rotation of the side mold module under load and rapid reset under no load, eliminating the time consumption of mold back-and-forth transportation and repeated alignment in traditional processes, making the production cycle compact and orderly. The automatic start of the attached vibrator ensures the density of concrete, and the dedicated steam curing station improves the curing quality. Overall, this step design reduces the production cycle and thus improves production efficiency.

[0022] Reference Figure 1The positioning unit includes a coarse positioning module and a fine positioning module. The coarse positioning module drives the two side molds of the side mold module to move to a position of 5-10mm from the mold closing position via hydraulic drive and then stops. The coarse positioning module controls the hydraulic pressure to be in a holding state. The fine positioning module controls the two side molds to move again, and the fine positioning module provides position feedback with a resolution of 0.01mm through a displacement sensor. When the two side molds reach their respective target positions and the left and right deviations are within 0.2mm, the mold closing operation is completed. When the positioning unit completes the mold closing operation, it automatically performs mechanical locking to fix the position of the two side molds.

[0023] In this embodiment, a two-stage control strategy of coarse positioning and fine positioning is adopted. First, the hydraulic drive quickly closes the mold to a position 5-10mm away from the target position and holds the pressure to avoid the impact and oscillation caused by direct fine positioning. This provides a stable mechanical reference for subsequent high-precision positioning. Therefore, this application not only ensures positioning efficiency, but also creates a low-stress, high-stability working condition for fine positioning, extending the service life of the side mold and hydraulic system. When the fine positioning module is working, it achieves sub-millimeter-level accuracy of side mold closing through closed-loop control of a 0.01mm high-resolution displacement sensor, which exceeds the accuracy of traditional manual mold closing. After closing, the mold is automatically mechanically locked to prevent the side mold from shifting or deforming during the pouring and vibration process. This ensures that the beam width and beam height of the precast small box girder are accurately consistent, reduces the workload of subsequent installation and adjustment, and improves the safety and durability of the bridge structure.

[0024] Reference Figure 1 The acquisition unit collects displacement data WL, vibration frequency data ZD, and pressure data YL on the side formwork surface when the side formwork module is working at the concrete pouring position, and sends them to the management unit. The management unit receives the data collected by the acquisition unit and calculates the judgment value P. The formula for calculating the judgment value P is as follows: In the formula, k1, k2, and k3 are all weighting coefficients, BZ1 is the standard safe displacement data, BZ2 is the standard safe vibration frequency data, and BZ3 is the standard safe pressure data. When selecting the weighting coefficients k1, k2, and k3 within the management unit, the standardized regression coefficient method of multiple linear regression is adopted. A regression model is established by combining the displacement data, vibration frequency data, and pressure data of the side mold surface with the defect index of side mold movement. All variables are standardized so that the absolute value of each regression coefficient directly reflects the degree of influence of each factor changing by one standard deviation on the quality defect. This absolute value is used as the original contribution of each factor, and the coefficients k1, k2, and k3 are obtained through normalization.

[0025] In this embodiment, a three-parameter fusion quantitative evaluation model is established, which integrates displacement data WL, vibration frequency data ZD, and pressure data YL on the side mold surface. This model normalizes multiple physical quantities into a single judgment value P, overcoming the shortcomings of single-parameter threshold judgment which is prone to false alarms or missed alarms. This application can comprehensively reflect the abnormal state during the mold-forming and casting process, providing a scientific and quantitative basis for the hierarchical early warning and intervention of the management unit. When selecting the weight coefficients k1, k2, and k3, the weight coefficients of each parameter are objectively and data-driven by multiple linear regression and standardized regression coefficient methods, avoiding the bias caused by subjective weighting, thereby improving accuracy and adaptability.

[0026] Reference Figure 1 The management unit compares the calculated judgment value P with its internal lower safety threshold 1Y and upper safety threshold Y2. When the judgment value P < the lower safety threshold Y1, the management unit continues production. When the lower safety threshold Y1 ≤ the judgment value P < the upper safety threshold Y2, the management unit issues an early warning. When the upper safety threshold Y2 ≤ the judgment value P, the management unit suspends production.

[0027] In this embodiment, the judgment value P is compared with its internal lower safety threshold 1Y and upper safety threshold Y2, and a three-level response mechanism is introduced to realize refined hierarchical management of the production process status. When the parameter deviates slightly, an early warning is issued to remind the operator to pay attention. When the parameter exceeds the standard seriously, production is automatically suspended to prevent the expansion of defects or equipment damage, avoid frequent shutdowns that affect efficiency, and promptly prevent major quality accidents, thus balancing production efficiency and safety.

[0028] Reference Figure 1 The quality inspection unit detects the dimensional data of the small box girder after production. The dimensional data includes beam width error (KW), beam height error (GW), camber (GD), and surface roughness (CC). The quality inspection unit analyzes the dimensional data. When any one or both of the beam width error (KW) and beam height error (GW) exceed their corresponding standard values, the quality inspection unit sends a positioning command to the management unit. When the camber (GD) exceeds the camber standard value, the quality inspection unit sends a pouring command to the management unit. When the surface roughness (CC) exceeds the surface roughness standard value, the quality inspection unit sends a curing command to the management unit. When none of the dimensional data detected by the quality inspection unit exceeds their corresponding standard values, the quality inspection unit does not send any commands and remains in standby mode. When the management unit receives a positioning command, it warns of a problem in the positioning process. When the management unit receives a pouring command, it warns of a problem in the pouring process. When the management unit receives a curing command, it warns of a problem in the curing process.

[0029] In this embodiment, the system maps the detected finished product size data to the process steps to achieve accurate traceability of quality defects. When a specific indicator exceeds the tolerance, the system automatically sends a corresponding instruction to the management unit, indicating that the fault may originate from the mold positioning, concrete pouring, or steam curing process. This provides a clear direction for rapid troubleshooting and process improvement, avoids the recurrence of similar defects, and triggers the instruction only when an excess is detected, avoiding interference from invalid information. The system distinguishes between three different instructions to help managers quickly locate the problematic process, shorten the fault response time, and improve the efficiency of quality management.

[0030] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented in software, the above embodiments can be implemented, in whole or in part, as a computer program product. The units and algorithm steps of the various examples described in the embodiments can be implemented in electronic hardware or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0031] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0032] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0033] In conclusion, the above description is only 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 should be included within the protection scope of the present invention.

Claims

1. An automated production system for prefabricated small box girders, characterized in that: It includes a production unit, a positioning unit, a data acquisition unit, a management unit, and a quality inspection unit. The production unit is used for the production of precast small box girders. The positioning unit is used for the mold positioning work during the production of the precast small box girders. The data acquisition unit is used to collect data during the mold production. The management unit is used for production work management. The quality inspection unit is used to inspect the dimensional data of the precast small box girders after production. The production unit includes a track module, a side mold module, and a workstation module. The track module is a parallel and continuous track arranged longitudinally along the production workshop. The track includes a conveying track for production and a return track for resetting. The side mold module is slidably installed on the track module. Each side mold module includes a bottom mold platform and two side molds arranged opposite each other. The workstation modules are arranged sequentially along the track module and include a steel reinforcement cage placement workstation, a concrete pouring workstation, a steam curing workstation, and a demolding and finishing workstation.

2. The automated production system for prefabricated small box girders according to claim 1, characterized in that: The production unit performs the following steps: Step S1: Hoist the tied steel reinforcement cage into the side formwork module of the steel reinforcement cage placement station, and the two side formworks in the side formwork module close together in the middle. Step S2: The side formwork module automatically travels along the conveying track inside the track module to the concrete pouring position, pours the concrete into the formwork, and the attached vibrator automatically starts at the same time. Step S3: After the pouring is completed, the side formwork module continues to move to the steam curing station to cure the box girder; Step S4: After the curing is completed, the side mold module is moved to the demolding and repair station. The side mold module opens automatically, and after demolding and repair, it is transported out. Step S5: The empty side formwork module returns to the steel reinforcement cage placement station via the turnover track to start the next production cycle.

3. The automated production system for prefabricated small box girders according to claim 1, characterized in that: The positioning unit includes a coarse positioning module and a fine positioning module. The coarse positioning module drives the two side molds of the side mold module to move to the mold closing position 5-10mm by hydraulic drive and then stops. The coarse positioning module controls the hydraulic pressure to be in a pressure holding state.

4. An automated production system for prefabricated small box girders according to claim 3, characterized in that: The precision positioning module controls the two side molds to move again, and the precision positioning module provides position feedback with a resolution of 0.01mm through the displacement sensor. When the two side molds reach their respective target positions and the left and right deviations are within 0.2mm, the mold closing operation is completed. When the positioning unit completes the mold closing operation, it automatically performs mechanical locking to fix the position of the two side molds.

5. An automated production system for prefabricated small box girders according to claim 1, characterized in that: The acquisition unit collects displacement data WL, vibration frequency data ZD, and pressure data YL on the side formwork surface when the side formwork module is working at the concrete pouring position, and sends them to the management unit. The management unit receives the data collected by the acquisition unit and calculates the judgment value P. The formula for calculating the judgment value P is as follows: In the formula, k1, k2 and k3 are all weighting coefficients, BZ1 is the standard safe displacement data, BZ2 is the standard safe vibration frequency data, and BZ3 is the standard safe pressure data.

6. An automated production system for prefabricated small box girders according to claim 5, characterized in that: When selecting the weight coefficients k1, k2, and k3 within the management unit, the standardized regression coefficient method of multiple linear regression is adopted. A regression model is established by combining displacement data, vibration frequency data, pressure data on the side mold surface, and defect indicators of side mold movement. All variables are standardized so that the absolute value of each regression coefficient directly reflects the degree of influence of each factor changing by one standard deviation on the quality defect. This absolute value is used as the original contribution of each factor, and the coefficients k1, k2, and k3 are obtained through normalization.

7. An automated production system for prefabricated small box girders according to claim 1, characterized in that: The management unit compares the calculated judgment value P with its internal lower safety threshold 1Y and upper safety threshold Y2. When the judgment value P < the lower safety threshold Y1, the management unit continues production. When the lower safety threshold Y1 ≤ the judgment value P < the upper safety threshold Y2, the management unit issues an early warning. When the upper safety threshold Y2 ≤ the judgment value P, the management unit suspends production.

8. An automated production system for prefabricated small box girders according to claim 1, characterized in that: The quality inspection unit checks the dimensional data of the small box girder after production. The dimensional data includes beam width error (KW), beam height error (GW), camber (GD), and surface roughness (CC). The quality inspection unit analyzes the dimensional data. When any one or both of the beam width error (KW) and beam height error (GW) exceed their corresponding standard values, the quality inspection unit sends a positioning command to the management unit. When the camber (GD) exceeds the standard camber value, the quality inspection unit sends a pouring command to the management unit. When the surface roughness (CC) exceeds the standard surface roughness value, the quality inspection unit sends a curing command to the management unit.

9. An automated production system for prefabricated small box girders according to claim 8, characterized in that: When the dimensional data detected by the quality inspection unit does not exceed its corresponding standard value, the quality inspection unit does not send an instruction and is in standby mode. When the management unit receives a positioning instruction, it warns of a problem with the positioning process. When the management unit receives a pouring instruction, it warns of a problem with the pouring process. When the management unit receives a curing instruction, it warns of a problem with the curing process.

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