High-precision adjustment intelligent sensing system for pc track beam and straight beam formwork

Abstract

The application discloses a PC track beam straight-line beam template high-precision adjustment intelligent sensing system, which comprises the following modules: a side template control module, which controls the opening and closing of side templates arranged on both sides of a production line; a data acquisition module, which acquires readings of upper displacement sensors and lower displacement sensors installed on fixed columns, one end of the upper displacement sensors and the lower displacement sensors being connected with the fixed columns and the other end being hinged with template back laths; a zero position reference modeling module, which records readings and generates a zero position reference data group according to the positions of the fixed columns, the upper and lower installation positions of the sensors and the positions of the side templates when the template zero position is calibrated; and a zero position consistency checking module, which checks the consistency of real-time zero position readings and the zero position reference data group when the template is at the zero position again, and outputs a reference available result. The application can realize the collaborative control of reference calibration, deviation solution, state judgment and adjustment traceability in the template adjustment process.

Description

Technical Field

[0001] This application relates to the field of PC track beam precast formwork adjustment and control technology, and in particular to a high-precision intelligent sensing system for PC track beam straight beam formwork adjustment. Background Technology

[0002] PC track beams are both precast beams and direct tracks for trains. Their alignment, top surface flatness, and spatial posture accuracy requirements are far higher than those of ordinary railway beams and highway beams. The horizontal and vertical curves, camber, and lateral superelevation of this type of track beam usually need to be formed in one precast stage, with almost no room for secondary adjustment. Therefore, the template system must not only be adjustable, but also have the ability to reproduce the changes at the millimeter level.

[0003] Existing technologies mostly achieve template opening and closing, lifting and lowering, and linear adjustment through adjustable bottom molds, side molds, end molds, or control devices, and mostly use manual verification or single-point verification to control molding accuracy. However, most of them focus on solving the problem of "whether the template can be adjusted in place", and pay insufficient attention to the transmission of subtle errors under high-precision working conditions, especially lacking continuous, linkage, and traceable judgment methods.

[0004] On the one hand, during manual fine-tuning of the template, the relative positions of height, pitch, verticality, and lateral are often coupled with each other. After a certain position is adjusted to meet the standard, it may simultaneously cause other positions to shift. Meeting the standard of local parameters does not mean that the overall spatial attitude is consistent. On the other hand, existing methods generally assume that the measurement benchmark is stable, which easily ignores measurement chain errors such as sensor support deflection, connection gaps, and zero-position drift after repeated opening and closing. This results in the template being in place when it is displayed, but not actually in place, making it difficult to meet the 1-2mm prefabrication accuracy requirements of PC track beams. Summary of the Invention

[0005] To address the aforementioned problems, embodiments of the present invention provide a high-precision intelligent sensing system for adjusting PC track beam straight beam formwork, the system comprising:

[0006] Side template control module: controls the opening and closing of the side templates located on both sides of the production line;

[0007] Data acquisition module: Collects readings from the upper displacement sensor and the lower displacement sensor installed on the fixed column. One end of the upper displacement sensor and the lower displacement sensor is connected to the fixed column, and the other end is hinged to the template back rib.

[0008] Zero-position reference modeling module: During template zero-position calibration, it records readings and generates zero-position reference data sets according to the fixed column position, sensor upper and lower installation positions, and side template position;

[0009] Zero-position consistency verification module: When the template is in the zero position again, the real-time zero-position reading is checked for consistency with the zero-position reference data group, and the reference usability result is output;

[0010] Deviation calculation module: When the available benchmark results meet the calling conditions, the real-time readings in the template closed state are compared with the zero-position benchmark data group to generate verticality deviation, height deviation, relative position deviation and pitch adjustment amount;

[0011] Linkage Judgment Module: Based on the correspondence between the upper and lower readings on the same fixed column and the correspondence between adjacent readings along the length of the side template, the module synchronously determines the verticality deviation, height deviation, relative position deviation, and pitch adjustment amount.

[0012] Adjustment command module: Based on the synchronization judgment result, output adjustment commands corresponding to the side template opening and closing, disc spring adjustment and lead screw adjustment;

[0013] Status synchronization module: Simultaneously displays the available benchmark results and synchronization status determination results on the control cabinet terminal and handheld terminal, and controls the output status of the column indicator light and control cabinet indicator light.

[0014] Furthermore, the zero-position reference data set includes a fixed column position marker, sensor upper and lower installation position markers, side template position markers, and zero-position readings corresponding to the markers.

[0015] Furthermore, the zero-position consistency verification module verifies the consistency between the real-time zero-position reading and the zero-position reference data group based on the difference between the upper and lower displacement readings on the same fixed column and the changes in the readings of adjacent fixed columns along the length direction of the side template.

[0016] Furthermore, the deviation calculation module generates a verticality deviation based on the difference between the upper displacement reading and the lower displacement reading on the same fixed column.

[0017] Furthermore, the deviation calculation module generates pitch adjustment and height deviation based on the difference in readings of adjacent fixed columns along the length of the side template.

[0018] Furthermore, the deviation calculation module generates a relative position deviation based on the difference in readings of the corresponding installation positions of the corresponding side templates on both sides of the production line.

[0019] Furthermore, the linkage judgment module outputs a positioning judgment when the verticality deviation, height deviation, relative position deviation, and pitch adjustment all meet the positioning conditions simultaneously; and outputs a non-positioning judgment and an item to be adjusted when one of the positioning conditions is not met.

[0020] Furthermore, when the adjustment command module outputs a pitch adjustment command, it corresponds to the disc spring adjustment position; when it outputs a height adjustment command, it corresponds to the lead screw adjustment position; and when it outputs an opening / closing adjustment command, it corresponds to the side template control system.

[0021] Furthermore, the status synchronization module synchronously sends the available benchmark results, verticality deviation, height deviation, relative position deviation, pitch adjustment amount, and synchronization arrival determination results to the control cabinet terminal, handheld terminal, column indicator light, and control cabinet indicator light. The column indicator light and control cabinet indicator light output a blue prompt when in the arrival state and a red prompt when not in the arrival state.

[0022] The high-precision adjustment intelligent sensing system for PC track beam straight beam formwork also includes a path correction module, which combines the current adjustment direction, historical readings at the corresponding position, and zero-point reference data set to identify and correct real-time reading differences caused by the adjustment direction switching, so as to generate corrected readings.

[0023] The technical effects and advantages of the intelligent sensing system for high-precision adjustment of PC track beam straight beam template provided by this invention are as follows:

[0024] This invention enables collaborative control during template adjustment, achieving calibrated benchmarks, solvable deviations, verifiable states, and traceable adjustments. By establishing a zero-point benchmark and verifying zero-point consistency, the invention first confirms the usability of the measurement benchmark before proceeding with subsequent deviation calculations, thus improving the reliability of adjustment decisions. It incorporates verticality, height, relative position, and pitch status into the same decision chain, avoiding mismatch in overall spatial attitude due to individual compliance. Based on the decision results, it directly outputs corresponding adjustment commands and synchronizes them to the terminal and indicator unit, facilitating rapid on-site identification, directional adjustment, and continuous verification. This forms a closed-loop control process from data acquisition, benchmark verification, deviation calculation to state output, which improves the reproducibility and consistency of template adjustment. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the connection of the intelligent sensing system for high-precision adjustment of the PC track beam linear beam template in Example 1;

[0026] Figure 2 This is a schematic diagram of the linkage determination process driven by the zero-position reference in Example 1;

[0027] Figure 3 This is a schematic diagram of the path correction linkage adjustment process in Example 2. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Example 1:

[0030] Please see Figure 1 As shown, an embodiment of the present invention provides a high-precision adjustment intelligent sensing system for PC track beam straight beam formwork, the system comprising:

[0031] Side template control module: controls the opening and closing of the side templates located on both sides of the production line;

[0032] Data acquisition module: Collects readings from the upper displacement sensor and the lower displacement sensor installed on the fixed column. One end of the upper displacement sensor and the lower displacement sensor is connected to the fixed column, and the other end is hinged to the template back rib.

[0033] Zero-position reference modeling module: During template zero-position calibration, it records readings and generates zero-position reference data sets according to the fixed column position, sensor upper and lower installation positions, and side template position;

[0034] Zero-position consistency verification module: When the template is in the zero position again, the real-time zero-position reading is checked for consistency with the zero-position reference data group, and the reference usability result is output;

[0035] Deviation calculation module: When the available benchmark results meet the calling conditions, the real-time readings in the template closed state are compared with the zero-position benchmark data group to generate verticality deviation, height deviation, relative position deviation and pitch adjustment amount;

[0036] Linkage Judgment Module: Based on the correspondence between the upper and lower readings on the same fixed column and the correspondence between adjacent readings along the length of the side template, the module synchronously determines the verticality deviation, height deviation, relative position deviation, and pitch adjustment amount.

[0037] Adjustment command module: Based on the synchronization judgment result, output adjustment commands corresponding to the side template opening and closing, disc spring adjustment and lead screw adjustment;

[0038] Status synchronization module: Simultaneously displays the available benchmark results and synchronization status determination results on the control cabinet terminal and handheld terminal, and controls the output status of the column indicator light and control cabinet indicator light.

[0039] In this embodiment, the zero-position reference data group is used to record the original readings in the zero-position calibration state of the template in a structured manner so that they can be called up in the subsequent template closing adjustment process. The side templates are set on both sides of the production line and are controlled by the control system to open and close. High-precision sensors are set on the outside of the templates. One end of the high-precision sensor is connected to the fixed column and the other end is hinged to the template back rib. The high-precision sensor is calibrated and the readings are recorded when the template is in the zero position. When the template is closed to the pouring state, the adjustment is made according to the recorded readings, and the terminal displays the adjustment results.

[0040] In specific implementation, the zero-position reference data set includes at least a fixed column position identifier, sensor upper and lower installation position identifiers, side template position identifiers, and zero-position readings corresponding to the identifiers. The fixed column position identifier indicates which fixed column the reading originates from and can be set along the template length in the arrangement order. The sensor upper and lower installation position identifiers distinguish the installation layers of the upper and lower sensors on the same fixed column, ensuring a one-to-one correspondence between upper and lower readings on the same column. The side template position identifier distinguishes whether the reading corresponds to the left or right template, or to a specific installation location on a particular side template. The zero-position reading refers to the reference value output by the corresponding high-precision sensor and collected and written into the zero-position reference data set when the template is in the zero-position calibration state. Zero position refers to the initial state where the side template is in a predetermined reference position, serving as a reference for subsequent adjustments. The position identifier is not limited to a specific encoding format; it can be a number, character, drawing number correspondence code, or a preset index within the terminal, as long as it can establish a unique correspondence between the sensor reading and the fixed column, installation layer, and side template position.

[0041] To prevent reading confusion during subsequent calls, when establishing the zero-point reference data group, the arrangement order of the fixed columns is first determined. Then, for each fixed column, the readings of the upper and lower sensors in the zero-point calibration state are collected separately, and these readings are associated and stored with the corresponding fixed column position identifier, sensor upper and lower installation position identifier, and side template position identifier. In this way, a single zero-point reading collected at the same time is not stored in isolation, but forms a traceable data record together with its corresponding column, installation layer, and side template position. When performing deviation calculations in the closed state of the template, the system calls the corresponding record in the zero-point reference data group and compares the real-time reading with the zero-point reading corresponding to the same fixed column, installation layer, and side template position, thereby avoiding cross-referencing readings from different columns, different layers, or different side template positions.

[0042] For example: when an upper sensor and a lower sensor are installed on a fixed column, two records can be generated respectively: "fixed column - upper installation position - side template position - corresponding zero-position reading" and "fixed column - lower installation position - side template position - corresponding zero-position reading". Another set of corresponding records is generated at another fixed column. When the terminal is displayed, the data is also called according to the aforementioned correspondence, so that when the operator adjusts the disc spring or lead screw, he / she can directly read the zero-position reference value and the current reading of the corresponding side template position. In the above way, the zero-position reference data group not only completes the storage of the zero-position reading, but also establishes the correspondence between the zero-position reading and the template spatial position, providing a unified data source for the subsequent determination of verticality, height and relative position.

[0043] like Figure 2As shown, in this embodiment, after the zero-position consistency verification module confirms that the real-time zero-position reading is available, the deviation calculation module further calculates the real-time reading in the template closed state to generate the verticality deviation. Combined with the sensor arrangement of this invention, an upper displacement sensor and a lower displacement sensor are installed on the same fixed column. The upper displacement sensor is used to collect the displacement reading at the upper connection position of the template back rib, and the lower displacement sensor is used to collect the displacement reading at the lower connection position of the template back rib. Both the upper and lower displacement readings refer to the real-time readings collected by the corresponding sensors and associated with the fixed column position marker, the sensor's upper and lower installation position markers, and the side template position marker when the template is in the current adjustment state. The verticality deviation refers to the vertical attitude deviation of the same side template at the corresponding fixed column relative to the zero-position reference state.

[0044] In practice, the deviation calculation module first retrieves the upper and lower displacement readings corresponding to the same fixed column and the same side template position, and calculates the current difference between them. Then, it retrieves the upper and lower zero-position readings corresponding to the same fixed column and side template position from the zero-position reference data group, and calculates the zero-position difference between them. Finally, it compares the current difference with the zero-position difference to obtain the verticality deviation. This "difference" is not simply the result of subtracting readings, but rather represents the relative displacement relationship between the upper and lower connection positions of the template back rib at the same fixed column. The data; when the side template only undergoes overall translation without tilting, the upper displacement reading and the lower displacement reading can change synchronously, but the difference between the two remains consistent with the zero-position difference; when the side template tilts at the fixed column, the difference between the upper displacement reading and the lower displacement reading will change relative to the zero-position difference, and the deviation calculation module will determine this change as the verticality deviation; to ensure that the calculation objects are not confused, the extraction of the current difference and the zero-position difference are both completed under the same fixed column position mark, the same sensor upper and lower installation position mark, and the same side template position mark.

[0045] For example:

[0046] At the same fixed column, the upper displacement sensor corresponds to the upper connection position of the template back rib, and the lower displacement sensor corresponds to the lower connection position of the template back rib. During zero-position calibration, a set of corresponding zero-position differences is formed. When the template is closed for adjustment, the deviation calculation module reads the upper and lower displacement readings at the fixed column again and calculates the current difference. If the current difference is consistent with the zero-position difference, no verticality deviation occurs at the fixed column. If the current difference changes relative to the zero-position difference, it indicates that the side template at this position has deviated from the zero-position state. The deviation calculation module generates the corresponding verticality deviation data accordingly and provides it for subsequent linkage judgment module to call. In this way, the verticality deviation is not directly given by the reading of a single sensor, but is derived from the corresponding difference between the upper and lower displacement readings on the same fixed column, so that the deviation data can directly correspond to the vertical attitude change of the template at this position.

[0047] In this embodiment, after the deviation calculation module generates the verticality deviation, it further generates the pitch adjustment and height deviation based on the difference in readings of adjacent fixed columns along the length of the side template. Combined with the sensor arrangement of this invention, the fixed columns are sequentially arranged along the length of the side template, forming a set of longitudinally adjacent positions between two adjacent fixed columns on the same side template. The adjacent fixed column readings refer to the real-time readings collected by the corresponding sensors of two adjacent fixed columns at the same vertical installation position on the same side template. The reading difference refers to the difference between the two real-time readings, or the change in the difference relative to the corresponding difference in the zero-point reference data set. The pitch adjustment refers to the adjustment amount corresponding to the change in height of the side template relative to the zero-point reference state along its length. The height deviation refers to the elevation deviation of the side template at the corresponding fixed column position relative to the zero-point reference state.

[0048] In specific implementation, the deviation calculation module first retrieves the real-time readings of two adjacent fixed columns along the length of the side template in the current adjustment state, according to the fixed column position markers, sensor upper and lower installation position markers, and side template position markers, and calculates the current reading difference between the adjacent fixed columns; then, it retrieves the zero-position reading corresponding to the adjacent fixed column from the zero-position reference data group and calculates the zero-position difference between the adjacent fixed columns; finally, it compares the current reading difference with the zero-position difference; if the comparison result changes, it indicates that the side template has undergone a longitudinal attitude change relative to the zero-position reference state in the adjacent section, and the deviation calculation is completed. The module generates the pitch adjustment amount accordingly. Since pitch changes affect the elevation relationship between adjacent positions, the deviation calculation module, after obtaining the pitch adjustment amount, continues to perform correlation calculations between the current reading and the zero-point reading at the corresponding fixed column position based on the changing relationship of the difference in readings between adjacent fixed columns, thereby generating the height deviation at that position. In other words, the pitch adjustment amount reflects the relative elevation change trend between adjacent positions, while the height deviation reflects the elevation deviation result formed after this change trend is applied to a specific fixed column position. Both are based on the corresponding comparison between the difference in readings between adjacent fixed columns and the zero-point difference.

[0049] For example:

[0050] The preceding and following fixed columns, arranged sequentially along the length of the side template, form a set of zero-position difference values ​​between adjacent fixed columns during zero-position calibration. During template closure adjustment, the deviation calculation module recalculates the current reading difference between these two points. If the current reading difference matches the zero-position difference, the pitch state of the adjacent section matches the zero-position reference state. If the current reading difference changes relative to the zero-position difference, it indicates a change in elevation between the adjacent section. The deviation calculation module generates a pitch adjustment amount based on this and further allocates this change to the corresponding fixed column position, forming corresponding height deviation data for subsequent linkage judgment module calls. In this way, the pitch adjustment amount and height deviation are not directly given by the isolated reading of a single fixed column, but are derived from the reading difference between adjacent fixed columns along the length of the side template, thus enabling the generated data to correspond to the continuous attitude changes of the side template within the longitudinal section.

[0051] In this embodiment, after the deviation calculation module generates the verticality deviation, height deviation, and pitch adjustment amount respectively, the relative position deviation is further generated based on the reading difference of the corresponding installation positions of the corresponding side templates on both sides of the production line. The side templates are set on both sides of the production line and are opened and closed by the control system. High-precision sensors are set on the outside of the templates. One end of the high-precision sensor is connected to the fixed column, and the other end is hinged to the back rib of the template. The high-precision sensor mainly monitors the verticality, height, and relative position of the template. The corresponding side templates refer to the two side templates that are set opposite to each other on both sides of the production line and jointly define the template working space. The corresponding installation position refers to the sensor installation position on the two side templates that has a corresponding relationship at the same longitudinal position and the same installation layer. The relative position deviation refers to the lateral relative deviation of the two side templates from the zero reference state at the corresponding installation position.

[0052] In specific implementation, the deviation calculation module first extracts real-time readings with corresponding relationships from the side templates on both sides of the production line based on the fixed column position markings, sensor upper and lower installation position markings, and side template position markings. Then, it calculates the current reading difference between the corresponding installation positions on both sides and retrieves the zero-position readings under the same corresponding relationship from the zero-position reference data group to calculate the zero-position difference between the corresponding installation positions on both sides. Next, it compares the current reading difference with the zero-position difference to obtain the relative position deviation. The aforementioned "current reading difference" characterizes the current relative spacing relationship between the two side templates at their corresponding installation positions under the template closure adjustment state. The zero-position difference characterizes the reference spacing relationship between the two side templates at the same corresponding installation position under the zero-position reference state. If the current reading difference is consistent with the zero-position difference, it indicates that the relative position of the two side templates at their corresponding installation positions remains consistent with the zero-position reference state. If the current reading difference changes relative to the zero-position difference, it indicates that the two side templates have experienced a lateral relative offset at their corresponding installation positions, and the deviation calculation module generates relative position deviation data accordingly.

[0053] To avoid cross-referencing of readings, the calculation of relative position deviation is carried out under the common constraints of the same fixed column position mark, the same sensor upper and lower installation position marks, and the corresponding side template position marks on both sides. In other words, the two sets of readings involved in the comparison should come from the corresponding installation positions on both sides of the production line at the same longitudinal position and in the same installation layer, rather than using readings from different longitudinal positions or different installation layers for mixed calculation. In this way, the correspondence between the templates on both sides is determined first, and then the current reading difference is compared with the zero position difference within this correspondence, so that the generated relative position deviation can directly correspond to the lateral change of the template working space at that position.

[0054] For example:

[0055] Sensors corresponding to the same installation level are installed at two corresponding fixed columns on both sides of the production line. During zero-position calibration, a set of zero-position difference values ​​are generated for the corresponding installation positions on both sides. When the template is closed for adjustment, the deviation calculation module rereads the real-time readings of the corresponding installation positions on both sides and calculates the current reading difference. If the current reading difference is inconsistent with the zero-position difference, it indicates that the opening and closing relationship of the two side templates at that position has changed relative to the zero-position reference state. The deviation calculation module then outputs the corresponding relative position deviation for subsequent linkage judgment module to call. In this way, the relative position deviation is not directly formed by the single-point reading of a single side template, but is derived from the reading difference of the corresponding side templates on both sides of the production line at the corresponding installation positions, thereby ensuring that the deviation data can reflect the relative spatial relationship between the two side templates.

[0056] In this embodiment, after the deviation calculation module generates verticality deviation, height deviation, relative position deviation, and pitch adjustment amount respectively, the linkage judgment module performs a unified judgment on the aforementioned calculation results to determine whether the current side formwork has reached the adjustment state for execution of pouring. In combination with the application scenario of this invention, the formwork adjustment is not completed independently for a single parameter, but rather the verticality, height, relative position, and pitch state are simultaneously affected during the opening and closing of the side formwork, the adjustment of the disc spring, and the adjustment of the screw. Therefore, the "in place judgment" refers to the comprehensive judgment result formed when the verticality deviation, height deviation, relative position deviation, and pitch adjustment amount all meet their respective in place conditions. The "not in place judgment" refers to the comprehensive judgment result formed when at least one of the aforementioned items does not meet the corresponding in place condition. The "item to be adjusted" refers to the deviation item or adjustment item that is identified as still needing to be adjusted under the "not in place judgment".

[0057] In practice, the linkage judgment module does not directly provide a final conclusion for a single deviation data point. Instead, it first reads the judgment states corresponding to verticality deviation, height deviation, relative position deviation, and pitch adjustment amount. For verticality deviation, the linkage judgment module determines whether the vertical attitude of the side template at the same fixed column has returned to the allowable range corresponding to the zero-position reference state. For height deviation, the linkage judgment module determines whether the elevation state at the corresponding fixed column position has returned to the allowable range corresponding to the zero-position reference state. For relative position deviation, the linkage judgment module determines whether the lateral relative relationship between the corresponding side templates on both sides of the production line at the corresponding installation positions has returned to the allowable range corresponding to the zero-position reference state. For pitch adjustment amount, the linkage judgment module determines whether the longitudinal attitude change between adjacent fixed columns along the length of the side template has returned to the allowable range corresponding to the zero-position reference state. When all of the above judgments are true, the linkage judgment module outputs a "positioning judgment." When any of the judgments is false, the linkage judgment module outputs a "not in position judgment" and marks the false item as an item to be adjusted. Thus, the final output result is not based on a single-point reading, but on the combined relationship of multiple deviations and adjustment amounts.

[0058] As a preferred implementation, the linkage determination module can calculate the comprehensive linkage determination value of the current fixed column position or the current adjustment section using the following formula:

[0059] ;

[0060] The determination result is then output using the following formula:

[0061] ;

[0062] In the formula, This indicates the comprehensive linkage judgment value of the current fixed column position or the current adjustment section; This indicates the determination result of the current fixed column position or the current adjustment section. A value of 1 indicates that the column is in place, and a value of 0 indicates that the column is not in place. This indicates the verticality deviation corresponding to the current fixed column position; This indicates the height deviation corresponding to the current fixed column position; This indicates the relative positional deviation of the corresponding side templates on both sides of the production line at their current corresponding installation positions; This indicates the pitch adjustment amount corresponding to the current adjustment section along the length of the side template; , , These represent the verticality deviation, height deviation, and relative position deviation relative to the current fixed column position or the position adjacent to the current adjustment section, respectively. , , , , These represent the weighting coefficients of verticality deviation, height deviation, relative position deviation, pitch adjustment, and adjacent position continuity deviation in the comprehensive linkage judgment, respectively. This indicates the threshold for comprehensive linkage judgment; This indicates the individual positioning conditions corresponding to the verticality deviation. This indicates the individual arrival conditions corresponding to the height deviation; This indicates the single-item positioning condition corresponding to the relative position deviation; This indicates the single-item positioning condition corresponding to the pitch adjustment amount.

[0063] Furthermore, to ensure that the items to be adjusted directly correspond to on-site adjustment actions, the linkage judgment module establishes a correspondence between the items to be adjusted and the sources of deviation when outputting the "not in place" judgment. Specifically, if the verticality deviation does not meet the in place condition, it corresponds to the attitude adjustment items in the pitch direction; if the height deviation does not meet the in place condition, it corresponds to the adjustment items in the vertical direction; if the relative position deviation does not meet the in place condition, it corresponds to the adjustment items in the opening and closing direction of the side template; if the pitch adjustment amount does not meet the in place condition, it corresponds to the section attitude adjustment items along the length direction of the side template. When the terminal displays the "not in place" status, it does not only display the "not in place" status, but also outputs the items to be adjusted simultaneously, so that the operators can continue to adjust the disc springs, lead screws, or side template control systems according to the direction corresponding to the items to be adjusted.

[0064] For example:

[0065] When both verticality deviation and height deviation meet the positioning conditions, but the relative position deviation does not, the linkage judgment module does not output a positioning judgment, but instead outputs a non-positioning judgment, and marks the adjustment item corresponding to the relative position as an item to be adjusted. After the item to be adjusted is completed, the linkage judgment module re-summarizes the judgment status of verticality deviation, height deviation, relative position deviation, and pitch adjustment, and only outputs a positioning judgment when all four simultaneously meet the positioning conditions. In this way, the linkage judgment module incorporates verticality deviation, height deviation, relative position deviation, and pitch adjustment into the same judgment chain, avoiding situations where a single parameter is in place but the overall spatial attitude is not.

[0066] In this embodiment, after the linkage judgment module outputs the non-position judgment and the item to be adjusted, the adjustment command module generates the corresponding adjustment command according to the type of the item to be adjusted, and outputs the adjustment command to the corresponding adjustment execution position. The operator can make fine adjustments to the template according to the template itself, adjust the template pitch by disc spring, adjust the template height by lead screw, and the side template is opened and closed by the control system. During the adjustment process, the data is displayed on the terminal and prompts whether the adjustment is in place. Therefore, the adjustment command is not a general prompt message, but a control information that establishes a corresponding relationship with the specific adjustment part and adjustment direction. The disc spring adjustment position refers to the position of the disc spring that undertakes the pitch adjustment function of the side template, the lead screw adjustment position refers to the position of the lead screw that undertakes the height adjustment function of the side template, and the side template control system refers to the control unit that executes the opening and closing of the side template.

[0067] In practice, the adjustment command module first reads the adjustment item output by the linkage judgment module and converts it according to the preset correspondence between the adjustment item and the actuator. When the attitude of the adjustment item in the pitch direction deviates, the adjustment command module generates a pitch adjustment command and associates the pitch adjustment command with the corresponding disc spring adjustment position. When the elevation of the adjustment item in the elevation direction deviates, the adjustment command module generates a elevation adjustment command and associates the elevation adjustment command with the corresponding lead screw adjustment position. When the lateral relative position between the two side templates deviates, the adjustment command module generates an opening and closing adjustment command and sends the opening and closing adjustment command to the side template control system. In this way, the vertical deviation, height deviation, relative position deviation and pitch adjustment amount generated by the deviation calculation module at the front end are further converted into adjustment commands with clear execution objects after unified judgment by the linkage judgment module, thereby avoiding the situation of only giving a "not in place" conclusion without a specific adjustment landing point.

[0068] Furthermore, when generating adjustment commands, the adjustment command module does not output them independently of the source of deviation. Instead, it retains the correspondence between the item to be adjusted and the fixed column position markers, the sensor upper and lower installation position markers, and the side template position markers. This allows the adjustment commands to be located at the corresponding side template, the corresponding installation section, and the corresponding adjustment point. When displayed on the terminal, the item to be adjusted can be displayed synchronously with the corresponding disc spring adjustment position, lead screw adjustment position, or side template control system. This allows operators to directly adjust based on the displayed adjustment objects. For example, when the linkage judgment module determines that a side template is not in the correct pitch direction in a certain section, the adjustment command module does not only output "not in the correct pitch direction," but also outputs the pitch adjustment command corresponding to that section and points to the disc spring adjustment position of that section. After the adjustment is completed, the data acquisition module re-acquires the readings and enters the next round of judgment. Through the above method, the adjustment command module establishes a closed-loop correspondence between the judgment result and the actual adjustment position, making the template adjustment process a continuous implementation path of "judgment - command - execution - retest."

[0069] In this embodiment, after the adjustment command module outputs the corresponding adjustment command and completes the retest, the status synchronization module is used to uniformly organize and send the available benchmark results, verticality deviation, height deviation, relative position deviation, pitch adjustment amount, and synchronization in place judgment results to the control cabinet terminal, handheld terminal, column indicator light, and control cabinet indicator light. The control cabinet and handheld terminal can display the adjustment data, and the column and control cabinet are equipped with light prompts. Blue light indicates that the adjustment is in place, and red light indicates that the adjustment is not in place. Therefore, status synchronization does not just display the same result separately, but summarizes the aforementioned judgment data according to a unified correspondence and outputs it simultaneously in two ways: terminal display and indicator light prompts, so that operators can obtain consistent status information in different working positions.

[0070] In practice, the status synchronization module first receives the baseline usable result output by the zero-position consistency verification module, the verticality deviation, height deviation, relative position deviation, and pitch adjustment amount output by the deviation calculation module, and the synchronization positioning judgment result output by the linkage judgment module. Then, according to the fixed column position mark, the sensor upper and lower installation position mark, and the side template position mark, the above results are merged to form status data corresponding to the current side template adjustment status. The baseline usable result refers to whether the real-time zero-position reading is allowed to be used as the basis for subsequent calculations after zero-position consistency verification. The synchronization positioning judgment result refers to the comprehensive result formed after the verticality deviation, height deviation, relative position deviation, and pitch adjustment amount are determined by linkage. After merging, the status synchronization module synchronously sends the status data to the control cabinet terminal and handheld terminal to display the current baseline status, deviation items, and positioning result. At the same time, the synchronization positioning judgment result is sent to the column indicator light and the control cabinet indicator light to output status prompts.

[0071] Furthermore, to ensure consistency between the terminal display and the on-site lighting prompts, the status synchronization module uses the synchronization completion determination result as the trigger basis for the indicator light output. When the synchronization completion determination result is in the "in place" state, the column indicator light and the control cabinet indicator light output a blue prompt; when the synchronization completion determination result is in the "out of place" state, the column indicator light and the control cabinet indicator light output a red prompt. At the same time, the control cabinet terminal and the handheld terminal not only display the color status, but also synchronously display the deviation items and adjustment amounts corresponding to the "out of place" state. This allows operators to directly identify the source of the "out of place" state after seeing the red prompt, and continue to perform disc spring adjustment, lead screw adjustment, or side template opening and closing adjustment accordingly. In other words, the indicator light provides a quick on-site identification function, while the control cabinet terminal and the handheld terminal provide a specific data viewing function. Both are uniformly driven by the status synchronization module based on the same determination result, thereby avoiding inconsistencies in status between different display carriers.

[0072] For example:

[0073] When the available benchmark results are valid and the verticality deviation, height deviation, relative position deviation, and pitch adjustment all meet the conditions for reaching the target, the status synchronization module displays the current adjustment result as being in place on both the control cabinet terminal and the handheld terminal. Simultaneously, it controls the column indicator and control cabinet indicator to output a blue alert. If any one of the conditions for reaching the target is not met, the status synchronization module displays the missing item and its corresponding data on the terminal and simultaneously controls the column indicator and control cabinet indicator to output a red alert. Through this method, the status synchronization module incorporates the benchmark verification results, deviation calculation results, and linkage judgment results into the same output link, creating an implementation path at the template adjustment site that features "consistent data judgment, different display positions, and synchronized output status."

[0074] Example 2:

[0075] like Figure 3As shown, this embodiment further improves upon the design of Embodiment 1. The difference lies in the fact that, in actual operation of Embodiment 1, it was found that after repeated opening and closing of the side formwork, and alternating pitch and height adjustments, when returning to the same target position from different adjustment directions, path-related differences existed in the upper displacement reading, lower displacement reading, and adjacent fixed column readings along the length of the side formwork. This caused the deviation calculation results to jump between adjacent adjustment cycles, failing to stably output the only item to be adjusted. Based on this, the high-precision adjustment intelligent sensing system for PC track beam straight beam formwork further includes a path correction module. This path correction module is positioned after the zero-position consistency verification module and before the deviation calculation module. The reason is that the zero-position consistency verification module first confirms that there is a callable relationship between the current real-time zero-position reading and the zero-position reference data group. On this basis, the path correction module then performs unified processing on the path-related differences in the adjustment process. The corrected reading is then input into the deviation calculation module to generate verticality deviation, height deviation, relative position deviation, and pitch adjustment. If the path correction module is set after the deviation calculation module, the aforementioned deviation data has already been generated based on the uncorrected reading. Subsequent correction will destroy the correspondence between verticality deviation, height deviation, relative position deviation, and pitch adjustment. Therefore, in this embodiment, the path correction module is arranged between the zero-position consistency verification module and the deviation calculation module.

[0076] In specific implementation, the path correction module does not change the zero-position reference data set itself, but performs path consistency processing on the real-time readings in the current adjustment cycle of the template. Path-related differences refer to the situation where, when the side template returns to the same target position from different adjustment methods or different adjustment directions, even if the current mechanical position tends to be consistent, there are still inconsistencies between the upper displacement reading, lower displacement reading, or adjacent fixed column readings. Path consistency processing refers to associating the current real-time reading with the current adjustment direction information, the corresponding reading information at the end of the previous adjustment cycle, and the zero-position reference data set to normalize the current real-time reading, so that it maintains a unified judgment basis before entering the deviation calculation module. The adjustment direction information can be composed of the execution direction corresponding to disc spring adjustment, lead screw adjustment, and side template opening and closing adjustment, which is used to characterize the adjustment path from which the current real-time reading is formed. The corresponding reading information refers to the previous round of reading records that are consistent with the current fixed column position identifier, the sensor upper and lower installation position identifier, and the side template position identifier.

[0077] In terms of implementation, the path correction module first receives the baseline available results output by the zero-position consistency verification module. When the baseline available results meet the calling conditions, it extracts the real-time reading of the current adjustment cycle according to the fixed column position identifier, the upper and lower sensor installation position identifiers, and the side template position identifier, and retrieves the historical reading of the corresponding position at the end of the previous adjustment cycle. Then, combined with the current adjustment direction information, it determines whether the current real-time reading belongs to abnormal fluctuations caused by path-related differences. If the current real-time reading and the historical reading maintain continuous change under the same adjustment direction, the path correction module directly outputs the current real-time reading. If the current real-time reading shows discontinuous change after the adjustment direction is switched, and the change cannot be explained by the zero-position consistency verification results, the path correction module uses the zero-position baseline data group as a benchmark to normalize the relationship between the current real-time reading and the historical reading, generates a corrected reading, and sends the corrected reading to the deviation calculation module. In the above way, the deviation calculation module does not call the unscreened original reading, but the unified reading basis after being processed by the path correction module.

[0078] For example: When the height of a fixed column is brought to the desired position by adjusting the lead screw in the previous round, and the pitch state of the same section is changed by adjusting the disc spring in the next round, although the side template returns to a position close to the same target, the upper and lower displacement readings on the same fixed column may show different changes compared to the previous round, and the reading difference between adjacent fixed columns may also change accordingly. At this time, the path correction module first identifies that the adjustment direction corresponding to the current round reading has changed, and then compares the current real-time reading with the corresponding reading of the previous round. If it is identified that the change is a path-related difference caused by the adjustment path switch, the correction reading is output for the deviation calculation module to call, instead of directly using the change as the source of new verticality deviation, height deviation, or pitch adjustment. Through this setting, when the linkage judgment module outputs the adjustment items in the subsequent rounds, it can form a stable judgment based on continuous and consistent calculation results, avoiding the situation where the adjustment items at the same position are repeatedly switched in adjacent adjustment rounds.

[0079] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

[0080] The above description is merely a preferred embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present application, based on the technical solution and concept of the present application, should be covered within the scope of protection of the present application.

Claims

1. A high-precision adjustment intelligent sensing system for PC track beam straight beam formwork, characterized in that, The system includes: Side template control module: controls the opening and closing of the side templates located on both sides of the production line; Data acquisition module: Collects readings from the upper displacement sensor and the lower displacement sensor installed on the fixed column. One end of the upper displacement sensor and the lower displacement sensor is connected to the fixed column, and the other end is hinged to the template back rib. Zero-position reference modeling module: During template zero-position calibration, it records readings and generates zero-position reference data sets according to the fixed column position, sensor upper and lower installation positions, and side template position; Zero-position consistency verification module: When the template is in the zero position again, the real-time zero-position reading is checked for consistency with the zero-position reference data group, and the reference usability result is output; Deviation calculation module: When the available benchmark results meet the calling conditions, the real-time readings in the template closed state are compared with the zero-position benchmark data group to generate verticality deviation, height deviation, relative position deviation and pitch adjustment amount; Linkage Judgment Module: Based on the correspondence between the upper and lower readings on the same fixed column and the correspondence between adjacent readings along the length of the side template, the module synchronously determines the verticality deviation, height deviation, relative position deviation, and pitch adjustment amount. Adjustment command module: Based on the synchronization judgment result, output adjustment commands corresponding to the side template opening and closing, disc spring adjustment and lead screw adjustment; Status synchronization module: Simultaneously displays the available benchmark results and synchronization status determination results on the control cabinet terminal and handheld terminal, and controls the output status of the column indicator light and control cabinet indicator light.

2. The high-precision adjustment intelligent sensing system for PC track beam straight beam formwork according to claim 1, characterized in that, The zero-position reference data set includes fixed column position markers, sensor upper and lower installation position markers, side template position markers, and zero-position readings corresponding to the markers.

3. The high-precision adjustment intelligent sensing system for PC track beam straight beam formwork according to claim 1, characterized in that, The zero-position consistency verification module verifies the consistency between the real-time zero-position reading and the zero-position reference data group based on the difference between the upper and lower displacement readings on the same fixed column and the changes in the readings of adjacent fixed columns along the length of the side template.

4. The high-precision adjustment intelligent sensing system for PC track beam straight beam formwork according to claim 1, characterized in that, The deviation calculation module generates the verticality deviation based on the difference between the upper and lower displacement readings on the same fixed column.

5. The high-precision adjustment intelligent sensing system for PC track beam straight beam formwork according to claim 1, characterized in that, The deviation calculation module generates pitch adjustment and height deviation based on the difference in readings of adjacent fixed columns along the length of the side template.

6. The high-precision adjustment intelligent sensing system for PC track beam straight beam formwork according to claim 1, characterized in that, The deviation calculation module generates a relative position deviation based on the difference in readings of the corresponding installation positions of the side templates on both sides of the production line.

7. The high-precision adjustment intelligent sensing system for PC track beam straight beam formwork according to claim 1, characterized in that, The linkage judgment module outputs a judgment when the verticality deviation, height deviation, relative position deviation, and pitch adjustment all meet the positioning conditions. If any one of the positioning conditions is not met, it outputs a judgment of non-positioning and an item to be adjusted.

8. The high-precision adjustment intelligent sensing system for PC track beam straight beam formwork according to claim 1, characterized in that, The adjustment command module outputs a pitch adjustment command corresponding to the disc spring adjustment position, an elevation adjustment command corresponding to the lead screw adjustment position, and an opening / closing adjustment command corresponding to the side template control system.

9. The high-precision adjustment intelligent sensing system for PC track beam straight beam formwork according to claim 1, characterized in that, The status synchronization module synchronously sends the available benchmark results, verticality deviation, height deviation, relative position deviation, pitch adjustment amount, and synchronization arrival determination results to the control cabinet terminal, handheld terminal, column indicator light, and control cabinet indicator light. The column indicator light and control cabinet indicator light output a blue prompt when in the arrival state and a red prompt when not in the arrival state.

10. The intelligent sensing system for high-precision adjustment of PC track beam straight beam formwork according to claim 1, characterized in that, Also includes: The path correction module is used to combine the current adjustment direction, the historical readings of the corresponding position, and the zero-point reference data set to identify and correct the real-time reading differences caused by the switching of the adjustment direction, so as to generate a corrected reading.

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