A hanging basket intelligent walking and positioning system for bridge construction and a control method thereof

Abstract

The application discloses a hanging basket intelligent walking and position adjusting system for bridge construction and a control method thereof, and relates to the technical field of bridge construction. A multi-module cooperative system is constructed to realize walking and anchoring coupled driving, rear anchor safety interlocking and full-working-condition dynamic position adjusting. The traditional hanging basket operation pain points are solved through digital twin prediction control. The application has the advantages that through the cooperative design of the walking and anchoring driving module and the rear anchor decoupling and reanchoring module, the safety interlocking logic of the central control module is matched, the industry inherent defects of the traditional hanging basket walking and anchoring mutual exclusion, the lack of active safety redundancy in the walking process, the poor synchronization of the multiple pushing mechanisms which easily causes deviation and jamming, and the complicated rear anchor dismounting process are optimized, the step-by-step driving architecture of the walking and anchoring coupling is adopted, the two-stage linkage rear anchor decoupling and reanchoring structure is matched, the dynamic anchoring locking of the hanging basket walking is realized, and the synchronous control of multiple trusses and the safety interlocking of the whole operation process are realized through the central control module.

Description

Technical Field

[0001] This invention relates to the field of bridge construction technology, specifically to an intelligent walking and positioning system for hanging baskets in bridge construction and its control method. Background Technology

[0002] In my country's transportation infrastructure construction sector, long-span prestressed concrete continuous beam bridges and continuous rigid frame bridges have become the mainstream bridge types in highways, railways, and municipal engineering projects, including those spanning rivers, mountain valleys, and urban interchanges, due to their core characteristics of high structural stiffness, smooth driving, strong spanning capacity, and excellent construction adaptability. As the core construction method for this type of bridge, the cantilever casting method does not require the erection of full-span scaffolding, has little impact on navigation, ground traffic, and the surrounding ecological environment, and can realize segmented and continuous construction of the main structure of the bridge under complex terrain and special working conditions. It has been widely and extensively applied in bridge engineering construction in China. Existing formwork movement and positioning equipment for cantilever bridge construction mainly relies on decentralized through-hole jacks to push the formwork forward, manual disassembly and assembly of the anchor bolts to switch anchorages, and the addition of temporary pads to adjust the formwork elevation. This method has certain drawbacks. First, formwork movement and anchoring are mutually exclusive, there is no active safety redundancy during movement, poor synchronization of multiple pushing mechanisms can easily lead to deviation and jamming, the disassembly and assembly of the anchor bolts is cumbersome, there is a high degree of reliance on manual labor, and the operation has significant safety risks. Second, the formwork elevation adjustment relies on the addition of temporary pads, which can easily lead to slippage and overturning hazards. It can only be statically pre-adjusted before pouring and cannot compensate for structural deformation during construction in real time. The control logic is lagging and the adjustment accuracy is insufficient. Therefore, we propose an intelligent formwork movement and positioning system and its control method for bridge construction. Summary of the Invention

[0003] The purpose of this invention is to provide an intelligent walking and positioning system for hanging baskets in bridge construction and its control method.

[0004] To achieve the above objectives, the present invention provides the following technical solution: an intelligent walking and positioning system for hanging baskets in bridge construction, the intelligent walking and positioning system comprising: Central control module: used to build a digital twin model that is mapped to the physical hanging basket in real time, and to simulate and predict the hanging basket's operating status and generate predictive control commands based on the collected real-time data, while coordinating the collaborative operation of the other modules. Walking and anchoring drive module: used to perform synchronous coupling operation of walking drive and dynamic anchoring during the forward movement of the hanging basket, so that the hanging basket is always in an effective anchoring and locking state throughout the entire movement, and the hanging basket moves forward smoothly and synchronously. Rear Anchor Decoupling and Re-anchoring Module: Used for synchronous decoupling, full-process pressure holding and pre-anchoring operations of the rear anchoring system of the hanging basket. It forms a safety interlock with the traveling anchoring drive module to perform one-click full-process operation of the rear anchor. Servo fine-tuning compensation module: used for stepless continuous adjustment of the effective length of the hanging basket sling, and to complete real-time dynamic compensation and attitude correction of the bottom formwork elevation under all working conditions of hanging basket travel and concrete pouring; Sensor acquisition module: used to collect displacement, force, attitude and position data in all dimensions throughout the entire process of hanging basket operation, and upload it to the central control module in real time; Safety interlock protection module: used for multi-level safety interlock protection and redundancy switching throughout the entire system operation process, and to automatically correct, alarm and safely shut down in the event of parameter over-limit or fault.

[0005] As a further aspect of the present invention: the central control module incorporates a 1:1 high-precision digital twin model of the hanging basket, a lightweight finite element calculation kernel, and a long short-term memory (LSM) time-series prediction unit. The digital twin model and the physical hanging basket are bidirectionally mapped through real-time data from the sensor acquisition module. The lightweight finite element calculation kernel is used to simulate the stress state and deformation trend of the hanging basket in real time. The LSM time-series prediction unit is used to predict the deviation trend of the future operating state of the hanging basket based on historical and real-time data, and generate predictive control commands. The synchronous displacement deviation prediction calculation formula of the LSM time-series prediction unit is as follows: ; in, For prediction The synchronous displacement deviation of each main truss at any given time is the core output of predictive control. for The input feature matrix at any given time includes real-time data collected from all dimensions, including the real-time displacement of each main truss, the hydraulic pressure of the drive cylinders, the travel speed, and the tilt angle of the hanging basket. for The hidden layer states of the Long Short-Term Memory network store short-term feature information of historical time-series data, capturing the instantaneous change patterns of the basket displacement. for By analyzing the cellular states of the long short-term memory network, long-term temporal-dependent feature information can be stored, capturing the cumulative deviation patterns during the basket's walking process. The pre-trained long short-term memory network prediction function is trained based on historical operation data and outputs the displacement deviation prediction value for future time. Based on the predicted displacement deviation value, the central control module sends a speed correction command to the walking anchor drive module in advance to achieve zero-deviation synchronous control of the hanging basket walking.

[0006] As a further embodiment of the present invention: the traveling anchoring drive module includes a top-pushing anchoring integrated hydraulic press unit corresponding to each main truss of the hanging basket, and a double-rail composite traveling anchoring integrated track. The double-rail composite traveling anchoring integrated track is provided with an upper flange traveling surface and a lower flange continuous toothed groove anchoring surface. The top-pushing anchoring integrated hydraulic press unit includes a bidirectional drive main cylinder, a front dynamic pawl anchoring unit, and a rear dynamic pawl anchoring unit. Both the front and rear dynamic pawl anchoring units are matched and meshed with the lower flange continuous toothed groove anchoring surface. The two ends of the bidirectional drive main cylinder are respectively hinged to the front and rear dynamic pawl anchoring units to form a stepping drive structure. The formula for calculating the matching control of the anchoring force and driving force of the traveling anchoring drive module is as follows: ; in, This is the minimum design anchoring force for the dynamic pawl anchoring unit, a core design parameter to ensure anchoring safety. A safety factor, with a value ≥ 2.5, is used to offset safety risks caused by load impacts and fluctuations in operating conditions. The maximum driving force of the bidirectional drive master cylinder is determined by the rated pressure of the hydraulic system and the effective working area of ​​the cylinder. This is the angle between the line of action of the driving force and the track axis, used to correct for the influence of the lateral component of the driving force. The core load parameters for the movement of the hanging basket are the total self-weight of the main truss and auxiliary structures. The longitudinal inclination angle of the track is used to correct for the influence of the self-weight component caused by the longitudinal slope of the bridge. The static friction coefficient between the pawl and the toothed anchoring surface is determined by the material of the contact surface and the machining accuracy. Throughout the entire process of the walking and anchoring drive module, at least one set of dynamic pawl anchoring units and the track are always locked and engaged, so as to realize the synchronous coupling operation of walking and anchoring.

[0007] As a further aspect of the present invention: the rear anchor decoupling and re-anchoring module includes a main rigid lifting beam, multiple controlled lifting units, and a synchronous jacking hydraulic unit. The main rigid lifting beam is fixedly connected to the upper ends of all the rear anchor threaded steel bars of the hanging basket. Each group of controlled lifting units corresponds to 2 to 3 rear anchor threaded steel bars. Each group of controlled lifting units is equipped with an independent pressure-holding jack and a pressure sensor. The lifting end of the synchronous jacking hydraulic unit acts on the main rigid lifting beam, and the hydraulic power input end is connected to the hydraulic power module pipeline. The calculation formula for the load-sharing control of a single threaded steel bar in the rear anchor decoupling and re-anchoring module is as follows: ; in, For the first The difference between the measured stress on the post-anchored precision-rolled threaded steel and the average stress on all threaded steel is the core control indicator for stress uniformity. This is the allowable coefficient for uneven stress distribution, with a value ≤ 0.05, ensuring that the stress deviation of all rear anchor threaded steel bars is controlled within five percent. The average stress value of all rear anchor precision rolled threaded steel bars is calculated by dividing the total lifting force by the total number of threaded steel bars. The rear anchor decoupling and re-anchoring module is linked with the safety interlocking guarantee module. The rear anchor decoupling operation can only be started after the walking anchoring drive module has completed the full locking confirmation. During the decoupling process, the stress of each threaded steel bar is adjusted in real time through the sub-control lifting unit to ensure that all threaded steel bars are subjected to uniform stress.

[0008] As a further aspect of the present invention: the servo fine-tuning compensation module is configured one-to-one with each sling of the hanging basket. Each servo fine-tuning compensation module includes a servo motor, a precision planetary reducer, a large-pitch trapezoidal screw pair, and a dual-redundant locking mechanism of hydraulic brake and mechanical locking. The output end of the servo motor is connected to the input end of the precision planetary reducer, and the output end of the precision planetary reducer is connected to the large-pitch trapezoidal screw pair. The two ends of the large-pitch trapezoidal screw pair are respectively fixedly connected to the main truss node of the hanging basket and the top of the sling. The dual-redundant locking mechanism of hydraulic brake and mechanical locking acts on the servo motor shaft and the trapezoidal screw pair respectively. The dynamic deflection compensation control calculation formula of the servo fine-tuning compensation module is: ; in, No. The real-time adjustment length compensation value of the sling is the core control input of the servo adjustment mechanism. For the first The theoretically effective length of the sling is pre-generated from the linear building information model of the completed bridge. For the first The real-time measured effective length of the sling is obtained by the displacement sensor. The deformation of the slings and truss structure caused by temperature changes is calculated from real-time data collected by temperature sensors. The deflection deformation of the hanging basket caused by concrete load and structural creep is calculated by real-time data collected by stress-strain sensors and laser rangefinders. The servo fine-tuning compensation module calculates the real-time compensation value based on the real-time collected deflection, stress, and temperature data using the above formula, and drives the servo motor to complete the stepless adjustment of the effective length of the sling, realizing dynamic closed-loop compensation of the bottom formwork elevation under all working conditions of hanging basket movement and concrete pouring.

[0009] As a further embodiment of the present invention: the sensing and acquisition module includes a magnetostrictive displacement sensor, a hydraulic pressure sensor, an anchoring force pressure sensor, a stress-strain sensor, a laser rangefinder, an inclination sensor, a wind speed sensor, and a meshing position sensor. The magnetostrictive displacement sensor is installed at each bidirectional drive main hydraulic cylinder and trapezoidal lead screw pair; the hydraulic pressure sensor is installed in each oil circuit branch of the hydraulic power module; the anchoring force pressure sensor is installed at the dynamic pawl anchoring unit and the sub-control lifting unit; the stress-strain sensor is installed at the main truss of the hanging basket and the sling; the laser rangefinder and inclination sensor are installed at the bottom formwork of the hanging basket; the wind speed sensor is installed at the top of the main truss of the hanging basket; and the meshing position sensor is installed at the meshing point between the dynamic pawl anchoring unit and the track. All sensors are bidirectionally connected to the central control module via an industrial bus to collect and upload real-time data on the full-dimensional status of the hanging basket operation.

[0010] As a further aspect of the present invention: the safety interlocking protection module includes a power redundancy unit, a control redundancy unit, a power supply redundancy unit, and a multi-level safety interlocking logic unit. The power redundancy unit includes a main hydraulic system and a backup hydraulic system. When the main hydraulic system fails, the backup hydraulic system seamlessly switches within 0.5 seconds. The control redundancy unit includes a main programmable logic controller and a backup programmable logic controller. When the main controller fails, the backup controller seamlessly takes over. The power supply redundancy unit includes a municipal power supply circuit, a diesel generator power supply circuit, and an uninterruptible power supply circuit. When the entire line loses power, the uninterruptible power supply support system completes safety locking and shutdown. The multi-level safety interlocking logic unit has built-in anchoring interlocking logic, overload protection logic, yaw protection logic, and fault self-diagnosis logic to realize closed-loop safety protection for the entire system operation process.

[0011] As a further aspect of the present invention: the hydraulic power module provides a unified hydraulic power source for the walking anchoring drive module and the rear anchor decoupling and re-anchoring module, realizing hydraulic collaborative control of multiple actuators. The hydraulic power module includes a hydraulic pump station, a proportional servo valve group, a hydraulic lock-up valve group, a pressure compensation valve group, and an oil circuit distribution unit. The output end of the hydraulic pump station is connected to the input end of the oil circuit distribution unit. Each output branch of the oil circuit distribution unit is connected to the corresponding actuator of the walking anchoring drive module and the rear anchor decoupling and re-anchoring module through the proportional servo valve group and the hydraulic lock-up valve group, respectively. The proportional servo valve group is bidirectionally connected to the central control module to receive control commands and adjust the flow and pressure of each branch, realizing synchronous collaborative control of multiple actuators. The pressure compensation valve group is used to ensure that the output pressure of each branch is not affected by load changes and to maintain control accuracy.

[0012] As a further aspect of the present invention: the intelligent walking and positioning system for the hanging basket also includes a human-machine interaction module. The human-machine interaction module is used to realize the input of work instructions, the visual display of system status, and the storage, traceability, and uploading management of construction data. The human-machine interaction module includes an industrial-grade touch screen human-machine interaction unit, a data storage unit, and a data uploading unit. The industrial-grade touch screen human-machine interaction unit is used for operators to input control instructions, view the real-time status of the system, and receive alarm information and fault prompts. The data storage unit is used to store sensor data, control instructions, work records, and alarm information throughout the entire hanging basket operation process, enabling traceability of the entire construction process. The data uploading unit is used to synchronously upload construction data to the bridge construction management platform and the building information modeling system, realizing the digital management of construction data.

[0013] In addition, this application also provides a method for intelligent walking and positioning control of hanging baskets in bridge construction, the method comprising the following steps: Step 1: Initialize the pre-control, import the linear model of the completed bridge, construct a digital twin that is bidirectionally mapped to the physical hanging basket, and complete the calibration of the sensor acquisition module and control parameters; Step 2: Safety interlock verification. Confirm that the walking anchor drive module is locked in place throughout the entire process, trigger the interlocking logic of the safety interlock protection module, and then verify the pre-tightening load distribution of the anchor decoupling and re-anchoring module. Step 3: Synchronous decoupling of the rear anchors. Start the rear anchor decoupling and re-anchoring module to complete the synchronous decoupling and full-process pressure holding of all rear anchor precision rolled threaded steel bars in one go. Step 4: Predictive synchronous walking. Based on the prediction results of the digital twin, the walking anchor drive module is driven to move forward step by step, maintaining at least one set of anchor locks throughout the process, and correcting synchronization deviations in real time. Step 5: Dynamic positioning under all working conditions. Through the servo fine-tuning compensation module, the posture of the hanging basket and the elevation of the bottom formwork are continuously fine-tuned during the movement. After reaching the position, dynamic compensation for the pouring deflection is completed. Step Six: In-place Re-anchor Locking. After the hanging basket is accurately positioned, the rear anchor decoupling and re-anchoring module is activated to complete the pre-anchoring and full anchoring locking, generating a full-process construction traceability report.

[0014] Compared with the prior art, the beneficial effects of the present invention by adopting the above technical solution are as follows: 1. This invention optimizes traditional hanging basket systems by employing a collaborative design of a walking and anchoring drive module and a rear anchor decoupling and re-anchoring module, coupled with the safety interlocking logic of a central control module. This addresses inherent industry shortcomings such as the mutual exclusion of walking and anchoring in traditional hanging basket systems, lack of active safety redundancy during walking, poor synchronization of multiple jacking mechanisms leading to skewing and jamming, and cumbersome rear anchor installation and removal procedures. It adopts a step-by-step drive architecture coupling walking and anchoring, combined with a two-stage linkage rear anchor decoupling and re-anchoring structure, to achieve dynamic anchoring and locking throughout the entire walking process of the hanging basket. Simultaneously, the central control module enables synchronous control of multiple trusses and safety interlocking throughout the entire operation process. This effectively reduces the risks of skewing, jamming, and overturning during hanging basket walking, improves the stability and safety of hanging basket forward movement, simplifies the rear anchor installation and removal process, and reduces the labor intensity of manual operation and the operational risks caused by human error.

[0015] 2. This invention optimizes traditional hanging basket elevation adjustments by employing a digital twin predictive control architecture in the central control module, coupled with a servo fine-tuning compensation module for a closed-loop adjustment design covering all working conditions. This addresses industry pain points such as the reliance on temporary pads for adjusting the formwork elevation, which can easily lead to slippage and overturning; the limitation to static pre-adjustment before pouring; the inability to compensate for structural deformation during construction in real time; and the lag in control logic. It replaces the traditional pad adjustment method with a stepless continuous servo adjustment structure, and, with real-time bidirectional mapping between the digital twin model and the physical hanging basket, achieves dynamic compensation and attitude correction of the bottom formwork elevation under all working conditions of the hanging basket's movement and concrete pouring. This effectively eliminates the risk of structural instability during elevation adjustment, improves the convenience and control accuracy of hanging basket attitude adjustment, optimizes the linear control effect during beam pouring, and adapts to the cantilever pouring construction needs under different working conditions. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the system flow in an embodiment of the present invention; Figure 2 This is a schematic diagram of the method steps in an embodiment of the present invention; Figure 3 This is a partial schematic diagram of the device in an embodiment of the present invention; Figure 4 This is a schematic diagram of the construction process in an embodiment of the present invention. Detailed Implementation

[0017] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. It should be noted that the description of these embodiments is for the purpose of helping to understand the present invention, but does not constitute a limitation of the present invention.

[0018] Furthermore, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0019] Please see the appendix Figure 1 - Appendix Figure 4 This invention discloses an intelligent walking and positioning system for hanging baskets used in bridge construction. The intelligent walking and positioning system for hanging baskets includes: Central control module: used to build a digital twin model that is mapped to the physical hanging basket in real time, and to simulate and predict the hanging basket's operating status and generate predictive control commands based on the collected real-time data, while coordinating the collaborative operation of the other modules. Walking and anchoring drive module: used to perform synchronous coupling operation of walking drive and dynamic anchoring during the forward movement of the hanging basket, so that the hanging basket is always in an effective anchoring and locking state throughout the entire movement, and the hanging basket moves forward smoothly and synchronously. Rear Anchor Decoupling and Re-anchoring Module: Used for synchronous decoupling, full-process pressure holding and pre-anchoring operations of the rear anchoring system of the hanging basket. It forms a safety interlock with the traveling anchoring drive module to perform one-click full-process operation of the rear anchor. Servo fine-tuning compensation module: used for stepless continuous adjustment of the effective length of the hanging basket sling, and to complete real-time dynamic compensation and attitude correction of the bottom formwork elevation under all working conditions of hanging basket travel and concrete pouring; Sensor acquisition module: used to collect displacement, force, attitude and position data in all dimensions throughout the entire process of hanging basket operation, and upload it to the central control module in real time; Safety interlock protection module: used for multi-level safety interlock protection and redundancy switching throughout the entire system operation process, and to automatically correct, alarm and safely shut down in the event of parameter over-limit or fault. Example

[0020] This embodiment is applied to a continuous rigid frame bridge project across a river on a highway. The main span of the bridge is a 120m+220m+120m prestressed concrete continuous rigid frame bridge. The box girder adopts a single-box, single-cell section, with a total of 22 cantilevered segments. The standard segment length is 3.5m, and the maximum segment weight is 2680kN. A rhomboid hanging basket is used for cantilevered construction. The intelligent walking and positioning system of the hanging basket in this embodiment is implemented as follows: 1. System Hardware and Parameter Configuration (1) Central control module: Siemens S7-1500 series PLC is used as the main controller, paired with an industrial-grade industrial computer, with a built-in 1:1 high-precision digital twin model of the hanging basket, a lightweight finite element calculation kernel and an LSTM timing prediction unit; The LSTM model was pre-trained based on historical data of the hanging basket operation of the first three segments of the bridge. The input feature dimension is 12-dimensional, including data such as displacement of each main truss, hydraulic cylinder pressure, travel speed, and tilt angle. The hidden layer dimension is 64-dimensional, the time step is 10, the prediction step is 2, and the sampling frequency is 100Hz.

[0021] (2) Walking and anchoring drive module: The hanging basket is equipped with two main trusses, each main truss corresponding to one set of top-pushing and anchoring integrated hydraulic unit and double-rail composite walking and anchoring integrated track; The track is made of Q355B steel, with an upper flange running surface width of 200mm, a lower flange continuous toothed groove anchoring surface toothed groove spacing of 50mm, and a tooth height of 15mm. The bidirectional drive main cylinder has a rated working pressure of 31.5MPa, a cylinder diameter of 160mm, a rod diameter of 100mm, a maximum stroke of 500mm, and a maximum driving force of 633kN. The pawl and tooth groove engagement depth of the front dynamic pawl anchoring unit and the rear dynamic pawl anchoring unit are ≥12mm, and the rated anchoring force of a single anchoring unit is ≥1600kN.

[0022] The anchoring force safety verification calculation in this embodiment is as follows: the total self-weight of the main truss and auxiliary structures is G = 850kN, and the longitudinal inclination angle of the track is... =0° (flat slope), angle between the line of action of the driving force and the track axis =0°, static friction coefficient =0.3, safety factor =2.5, substitute into the calculation formula for matching and controlling anchoring force and driving force: ; Substituting the parameters, we get: ≥ ; Considering the most unfavorable skew condition, the hanging basket exhibits a 2° skew. =2°, =0°, substituting into the calculation, we get: ; The single anchoring unit selected in this embodiment has a rated anchoring force of 1600kN, which is much greater than the minimum anchoring force required by calculation, thus meeting the safety requirements.

[0023] (3) Rear Anchor Decoupling and Re-anchoring Module: One main rigid lifting beam is installed, made of double-section HM588×300 H-beams, with a length of 6.5m; a total of 18 rear anchor precision rolled threaded steel bars are installed, with specifications of PSB930- 32. Nine control lifting units are set up, each control lifting unit corresponds to two precision rolled threaded steel bars, and each group is equipped with one pressure holding jack with a rated tonnage of 200kN. The synchronous lifting hydraulic unit uses two lifting jacks with a rated tonnage of 500kN and a rated working pressure of 31.5MPa.

[0024] In this embodiment, the load-sharing control verification is as follows: Total lifting force Ftotal = 18 × 150 kN = 2700 kN, and the average force on a single threaded steel bar is... =150kN, allowable stress unevenness coefficient δ=0.05, that is, the maximum allowable stress difference ≤0.05×150=7.5kN; In this embodiment, the pressure sensor of the separately controlled lifting unit has a measurement accuracy of 0.5 class, which can control the actual force deviation within 3kN, thus meeting the control requirements.

[0025] (4) Servo fine-tuning compensation module: The basket is equipped with a total of 8 slings, and each sling corresponds to 1 set of servo fine-tuning compensation module; the servo motor is a 1.5kW AC servo motor with a rated speed of 3000r / min; the precision planetary reducer has a reduction ratio of 1:60; the large pitch trapezoidal screw pair has a specification of Tr80×10, an effective adjustment stroke of 0-150mm, and an adjustment accuracy of 0.05mm; the hydraulic brake has a rated braking torque of 20N・m, and the mechanical locking nut adopts a fine-tooth locking structure to form a double redundant locking.

[0026] The dynamic deflection compensation calculation in this embodiment is based on the theoretically effective length of the third sling during the casting of a certain segment. =3200mm, effective length measured in real time =3188mm, temperature deformation =+1.2mm, creep deformation under load =+6.8mm, substitute into the dynamic deflection compensation control calculation formula: ; The calculation yields: =3200−(3188+1.2+6.8)=4mm The system automatically drives the servo motor to rotate, causing the lead screw to extend by 4mm to complete dynamic compensation and ensure that the bottom mold elevation always meets the design requirements.

[0027] (5) Sensor acquisition module: Each bidirectional drive main cylinder is equipped with one magnetostrictive displacement sensor with a measurement range of 0-500mm and an accuracy of ±0.05mm; each hydraulic cylinder is equipped with one hydraulic pressure sensor with a range of 0-40MPa and an accuracy of 0.5 grade; each sling is equipped with one stress strain sensor with a range of 0-2000MPa and an accuracy of 0.2 grade; the bottom formwork frame is equipped with four laser distance sensors with a range of 0-500mm and an accuracy of ±0.1mm, and two dual-axis tilt sensors with a measurement range of ±30° and an accuracy of 0.01°; the top of the main truss is equipped with one wind speed sensor with a range of 0-60m / s; each dynamic pawl anchoring unit is equipped with one engagement proximity switch; all sensors are connected to the central control module via Profinet industrial bus.

[0028] (6) Safety interlocking protection module: The power redundancy unit is equipped with a main hydraulic pump station and a backup hydraulic pump station, and the backup pump station can complete seamless switching within 0.5 seconds; the control redundancy unit is equipped with a main PLC and a backup PLC, with hot standby redundancy; the power supply redundancy unit is equipped with municipal power supply, a 100kW diesel generator and a 10kVA UPS uninterruptible power supply, and the UPS can support the system to run at full load for 30 minutes; built-in anchoring interlock, overload protection, yaw protection and fault self-diagnosis logic.

[0029] (7) Hydraulic power module: It is equipped with a hydraulic pump station with a rated flow of 40L / min and a rated pressure of 31.5MPa, and is equipped with a proportional servo valve group, a hydraulic lock-up valve group, and a pressure compensation valve group. The oil circuit distribution unit corresponds to 8 hydraulic branches, and each branch is equipped with an independent proportional servo valve and a pressure sensor.

[0030] (8) Human-computer interaction module: Equipped with a 15-inch industrial-grade touch screen, it has functions for inputting work instructions, displaying status in real time, prompting alarm information, and storing and uploading data. The data storage unit can store no less than 5 years of work data and supports data docking with bridge construction management platform and BIM system.

[0031] 2. Work Process and Implementation Results This embodiment completes the hanging basket walking and repositioning operation according to the following steps: Step 1: Initialize the pre-control. Import the completed linear BIM model of the bridge into the central control module, construct a digital twin that is 1:1 bidirectionally mapped to the physical hanging basket, and complete the zero-point calibration of the sensor acquisition module and the initial setting of control parameters, including the synchronization error threshold of 2mm, the oil pressure safety threshold of 35MPa, and the anchoring force threshold of 200kN. Step 2: Safety interlock verification. The central control module sends a locking command to the walking anchor drive module to confirm that the front and rear dynamic pawl anchor units are fully engaged with the track tooth grooves and the anchoring force meets the standard, thus triggering the anchoring interlock logic. At the same time, the sub-control lifting unit is started to complete the pre-tightening and load equalization of the 18 fine-rolled threaded steel bars, ensuring that the force deviation of a single bar is ≤3kN. Step 3: Rear anchor synchronous decoupling. The central control module issues the rear anchor decoupling command, and the hydraulic unit synchronously lifts the main rigid lifting beam, completing the synchronous decoupling of all fine rolled threaded steel bars in one go. The sub-control lifting unit maintains pressure throughout the process, and the operators quickly remove the nuts and washers. The decoupling process takes 7 minutes. Step 4: Predictive synchronous walking. The central control module, based on the LSTM timing prediction unit, collects walking data in real time, predicts the displacement deviation of the next two steps, and issues speed correction commands in advance to drive the walking anchor drive module to move forward step by step. Each step cycle always maintains at least one set of pawl anchor units locked. The single step distance is 500mm, and a total of 7 step cycles are completed to achieve a 3.5m segment forward movement. During the walking process, the synchronization error of the two main trusses is always controlled within 1.2mm, without any deviation or jamming. The walking process takes 32 minutes. Step 5: Dynamic positioning under all working conditions. During the movement, the system collects the hanging basket posture data in real time and adjusts the effective length of each sling in sync through the servo fine-tuning compensation module to complete the stepless fine-tuning of the bottom formwork elevation and levelness. The coarse adjustment is completed when the formwork is in place. During the concrete pouring process, the system collects deflection, stress, and temperature data in real time, dynamically calculates the compensation amount, adjusts the sling length in real time, and dynamically compensates the bottom formwork elevation throughout the process. After the pouring is completed, the maximum deviation of the bottom formwork elevation is 2.1mm. Step Six: Re-anchoring and locking. After the hanging basket is accurately positioned, the rear anchor decoupling and re-anchoring module is activated to complete the pre-anchoring. The operator tightens the main nut to complete the full anchoring and locking. The system automatically generates and uploads a full-process construction traceability report. The re-anchoring process takes 4 minutes.

[0032] The final results of this embodiment are as follows: the total time for the entire process of hanging basket walking, adjusting and anchoring is 43 minutes, only 3 people are required (1 person to operate and 2 people to inspect), the synchronization error of multi-truss walking is ≤1.2mm, the linear control deviation of the completed bridge is ≤2.1mm, there is no safety gap throughout the process, and all indicators are far superior to the industry standard. Example

[0033] This embodiment is applied to a continuous beam bridge project with a large longitudinal slope on a mountain highway. The main span of the bridge is an 80m+150m+80m prestressed concrete continuous beam bridge with a longitudinal slope of 4.2%. There are 16 cantilevered segments, with a standard segment length of 4m. The construction adopts a triangular hanging basket. The architecture of the intelligent walking and positioning system of the hanging basket in this embodiment is the same as that in Embodiment 1. The core parameters and working conditions are adapted and optimized as follows: The traveling anchoring drive module consists of three main trusses, each corresponding to one set of integrated hydraulic jacking and anchoring unit. The bidirectional drive main cylinder has a rated tonnage of 800kN and a maximum stroke of 400mm. The longitudinal inclination angle of the track is consistent with the longitudinal slope of the bridge at 4.2°. The safety factor k is taken as 3.0. Substituting into the anchoring force calculation formula, the minimum anchoring force is calculated to be ≥426kN. A single anchoring unit with a rated anchoring force of 2000kN is selected to meet the safety requirements of the large longitudinal slope condition. Servo fine-tuning compensation module: A total of 12 slings are set up, corresponding to 12 sets of servo fine-tuning compensation modules, which can effectively adjust the stroke from 0-200mm, adapting to the elevation adjustment requirements of steep longitudinal slope conditions. Control parameter optimization: The input features of the LSTM timing prediction unit are increased to include track inclination angle and longitudinal slope self-weight force compensation terms. The walking synchronization error threshold is set to 1.5mm. The safety interlocking logic is optimized for steep longitudinal slope conditions, and anti-runaway protection function is added.

[0034] The final results of this embodiment are as follows: the entire process of the hanging basket traveling in a single 4m segment takes 38 minutes, with 3 workers, and the synchronization error of the 3 main trusses is ≤1.4mm. After dynamic deflection compensation during the pouring process, the maximum deviation of the bottom formwork elevation is 2.4mm. There are no slippage or tilting phenomena throughout the process, which perfectly adapts to the construction requirements of complex conditions on a large longitudinal slope.

[0035] Comparative Example This comparative example uses the same bridge engineering and the same diamond-shaped hanging basket main structure as Example 1. The difference lies in the adoption of a traditional hanging basket travel and adjustment system commonly used in the industry, with the specific configuration as follows: The walking system uses four distributed through-hole jacks, which are manually operated and controlled to push the vehicle. There is no synchronous control or sensor acquisition system. The walking track is a regular I-beam track without anchoring grooves or dynamic anchoring units. The rear anchoring is completely released before walking. Rear Anchor System: 18 PSB930 anchors of the same specifications as in Example 1 are used. 32mm precision rolled threaded steel bars are unloaded and dismantled one by one using a single jack; The elevation adjustment system uses a combination of sling hole adjustment and temporary steel plate padding for elevation adjustment, without servo fine-tuning or dynamic compensation mechanisms. Control system: There is no integrated intelligent control system; the entire process is operated and inspected manually.

[0036] The table below shows a comparison of the core performance indicators of this comparative example and the two embodiments:

[0037] As can be seen from the comparison of the comparative examples and the two embodiments, the present invention solves the core pain points of traditional hanging basket systems, such as low efficiency, poor accuracy and high safety risks, whether in conventional flat slope working conditions or complex long-slope working conditions. It has outstanding substantive features and significant progress.

[0038] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Any variations and modifications can be made by those skilled in the art without departing from the spirit and scope of the invention. Therefore, any modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention, without departing from the scope of the invention, fall within the protection scope defined by the claims of the present invention.

Claims

1. A smart walking and positioning system for hanging baskets in bridge construction, characterized in that, The hanging basket intelligent walking and positioning system includes: Central control module: used to build a digital twin model that is mapped to the physical hanging basket in real time, and to simulate and predict the hanging basket's operating status and generate predictive control commands based on the collected real-time data, while coordinating the collaborative operation of the other modules. Walking and anchoring drive module: used to perform synchronous coupling operation of walking drive and dynamic anchoring during the forward movement of the hanging basket, so that the hanging basket is always in an effective anchoring and locking state throughout the entire movement, and the hanging basket moves forward smoothly and synchronously. Rear Anchor Decoupling and Re-anchoring Module: Used for synchronous decoupling, full-process pressure holding and pre-anchoring operations of the rear anchoring system of the hanging basket. It forms a safety interlock with the traveling anchoring drive module to perform one-click full-process operation of the rear anchor. Servo fine-tuning compensation module: used for stepless continuous adjustment of the effective length of the hanging basket sling, and to complete real-time dynamic compensation and attitude correction of the bottom formwork elevation under all working conditions of hanging basket travel and concrete pouring; Sensor acquisition module: used to collect displacement, force, attitude and position data in all dimensions throughout the entire process of hanging basket operation, and upload it to the central control module in real time; Safety interlock protection module: used for multi-level safety interlock protection and redundancy switching throughout the entire system operation process, and to automatically correct, alarm and safely shut down in the event of parameter over-limit or fault.

2. The intelligent walking and positioning system for hanging baskets in bridge construction according to claim 1, characterized in that: The central control module incorporates a 1:1 digital twin model of the hanging basket, a lightweight finite element calculation kernel, and a long short-term memory (LSM) time-series prediction unit. The digital twin model and the physical hanging basket are bidirectionally mapped through real-time data from the sensor acquisition module. The lightweight finite element calculation kernel is used to simulate the stress state and deformation trend of the hanging basket in real time. The LSM time-series prediction unit is used to predict the deviation trend of the hanging basket's future operating state based on historical and real-time data, generating predictive control commands. The synchronous displacement deviation prediction calculation formula of the LSM time-series prediction unit is as follows: ； in, For prediction The synchronous displacement deviation of each main truss at any given time is the output of the predictive control. for The input feature matrix at any given time includes real-time data collected from all dimensions, including the real-time displacement of each main truss, the hydraulic pressure of the drive cylinders, the travel speed, and the tilt angle of the hanging basket. for The hidden layer states of the Long Short-Term Memory network store short-term feature information of historical time-series data, capturing the instantaneous change patterns of the basket displacement. for By analyzing the cellular states of the long short-term memory network, long-term temporal-dependent feature information can be stored, capturing the cumulative deviation patterns during the basket's walking process. This is a pre-trained prediction function for a long short-term memory network, trained based on historical task data, and outputs the predicted displacement deviation value for future time moments.

3. The intelligent walking and positioning system for hanging baskets in bridge construction according to claim 2, characterized in that: The traveling anchoring drive module includes a top-pushing anchoring integrated hydraulic press unit corresponding to each main truss of the hanging basket, and a double-rail composite traveling anchoring integrated track. The double-rail composite traveling anchoring integrated track is provided with an upper flange traveling surface and a lower flange continuous toothed groove anchoring surface. The top-pushing anchoring integrated hydraulic press unit includes a bidirectional drive main cylinder, a front dynamic pawl anchoring unit, and a rear dynamic pawl anchoring unit. The front and rear dynamic pawl anchoring units are matched and meshed with the lower flange continuous toothed groove anchoring surface. The two ends of the bidirectional drive main cylinder are respectively hinged to the front and rear dynamic pawl anchoring units to form a stepping drive structure. The calculation formula for the matching control of the anchoring force and driving force of the traveling anchoring drive module is as follows: ； in, The minimum design anchoring force for the dynamic pawl anchoring unit. For safety margin, a value ≥ 2.5 is used. The maximum driving force of the bidirectional drive master cylinder is determined by the rated pressure of the hydraulic system and the effective working area of ​​the cylinder. The angle between the line of action of the driving force and the axis of the track. The core load parameters for the movement of the hanging basket are the total self-weight of the main truss and auxiliary structures. The longitudinal inclination angle of the track is used to correct for the influence of the self-weight component caused by the longitudinal slope of the bridge. The static friction coefficient between the pawl and the toothed anchoring surface is determined by the material of the contact surface and the machining accuracy. Throughout the entire process of the walking anchoring drive module, at least one set of dynamic pawl anchoring units and the track are always in a locked engagement state.

4. The intelligent walking and positioning system for hanging baskets in bridge construction according to claim 3, characterized in that: The rear anchor decoupling and re-anchoring module includes a main rigid lifting beam, multiple controlled lifting units, and a synchronous jacking hydraulic unit. The main rigid lifting beam is fixedly connected to the upper ends of all the rear anchor threaded steel bars of the hanging basket. Each controlled lifting unit corresponds to 2 to 3 rear anchor threaded steel bars. Each controlled lifting unit is equipped with an independent pressure-holding jack and a pressure sensor. The jacking end of the synchronous jacking hydraulic unit acts on the main rigid lifting beam, and the hydraulic power input end is connected to the hydraulic power module pipeline. The calculation formula for the load-sharing control of a single threaded steel bar in the rear anchor decoupling and re-anchoring module is as follows: ； in, For the first The difference between the measured stress on the threaded steel bar after anchoring and the average stress on all threaded steel bars. This is the allowable coefficient for uneven stress distribution, with a value ≤ 0.

05. The average stress value of all rear anchor precision rolled threaded steel bars is calculated by dividing the total lifting force by the total number of threaded steel bars. The rear anchor decoupling and re-anchoring module is linked with the safety interlocking guarantee module. The rear anchor decoupling operation can only be started after the walking anchoring drive module has completed the full locking confirmation. During the decoupling process, the stress of a single threaded steel bar is adjusted in real time through the sub-control lifting unit.

5. The intelligent walking and positioning system for hanging baskets in bridge construction according to claim 4, characterized in that: The servo fine-tuning compensation module is configured one-to-one with each sling of the hanging basket. Each servo fine-tuning compensation module includes a servo motor, a precision planetary reducer, a large-pitch trapezoidal screw pair, and a dual-redundant locking mechanism of hydraulic brake and mechanical locking. The output end of the servo motor is connected to the input end of the precision planetary reducer, and the output end of the precision planetary reducer is drivenly connected to the large-pitch trapezoidal screw pair. The two ends of the large-pitch trapezoidal screw pair are fixedly connected to the main truss node of the hanging basket and the top of the sling, respectively. The dual-redundant locking mechanism of hydraulic brake and mechanical locking acts on the servo motor shaft and the trapezoidal screw pair, respectively. The dynamic deflection compensation control calculation formula of the servo fine-tuning compensation module is: ； in, For the first Real-time adjustment length compensation value of the sling. For the first The theoretically effective length of the sling is pre-generated from the architectural information model of the completed bridge. For the first The real-time measured effective length of the sling is obtained by the displacement sensor. The deformation of the slings and truss structure caused by temperature changes is calculated from real-time data collected by temperature sensors. The deflection deformation of the hanging basket caused by concrete load and structural creep is calculated from real-time data collected by stress-strain sensors and laser rangefinders.

6. The intelligent walking and positioning system for hanging baskets in bridge construction according to claim 5, characterized in that: The sensing and acquisition module includes a magnetostrictive displacement sensor, a hydraulic pressure sensor, an anchoring force pressure sensor, a stress-strain sensor, a laser rangefinder, a tilt sensor, a wind speed sensor, and a meshing position sensor. The magnetostrictive displacement sensor is installed at each bidirectional drive main hydraulic cylinder and trapezoidal lead screw pair. The hydraulic pressure sensor is installed in each oil circuit branch of the hydraulic power module. The anchoring force pressure sensor is installed at the dynamic pawl anchoring unit and the sub-control lifting unit. The stress-strain sensor is installed at the main truss of the hanging basket and the sling. The laser rangefinder and tilt sensor are installed at the bottom formwork of the hanging basket. The wind speed sensor is installed at the top of the main truss of the hanging basket. The meshing position sensor is installed at the meshing point between the dynamic pawl anchoring unit and the track. All sensors are bidirectionally connected to the central control module via an industrial bus to collect and upload real-time data on the full-dimensional status of the hanging basket operation.

7. The intelligent walking and positioning system for hanging baskets in bridge construction according to claim 6, characterized in that: The safety interlocking protection module includes a power redundancy unit, a control redundancy unit, a power supply redundancy unit, and a multi-level safety interlocking logic unit. The power redundancy unit includes a main hydraulic system and a backup hydraulic system. In the event of a failure in the main hydraulic system, the backup hydraulic system seamlessly switches over within 0.5 seconds. The control redundancy unit includes a main programmable logic controller and a backup programmable logic controller. In the event of a failure in the main controller, the backup controller seamlessly takes over. The power supply redundancy unit includes a municipal power supply circuit, a diesel generator power supply circuit, and an uninterruptible power supply (UPS) circuit. In the event of a complete power outage, the UPS system completes safety locking and shutdown. The multi-level safety interlocking logic unit incorporates anchoring interlocking logic, overload protection logic, yaw protection logic, and fault self-diagnosis logic.

8. The intelligent walking and positioning system for hanging baskets in bridge construction according to claim 7, characterized in that: The hydraulic power module provides a unified hydraulic power source for the traveling anchoring drive module and the rear anchor decoupling and re-anchoring module. The hydraulic power module includes a hydraulic pump station, a proportional servo valve group, a hydraulic lock-up valve group, a pressure compensation valve group, and an oil circuit distribution unit. The output end of the hydraulic pump station is connected to the input end of the oil circuit distribution unit. Each output branch of the oil circuit distribution unit is connected to the corresponding actuator of the traveling anchoring drive module and the rear anchor decoupling and re-anchoring module through the proportional servo valve group and the hydraulic lock-up valve group, respectively.

9. The intelligent walking and positioning system for hanging baskets in bridge construction according to claim 8, characterized in that: The intelligent walking and positioning system for the hanging basket also includes a human-machine interaction module. This module is used to input work instructions, visualize the system status, and store, trace, and upload construction data. The human-machine interaction module includes an industrial-grade touch screen human-machine interaction unit, a data storage unit, and a data upload unit. The industrial-grade touch screen human-machine interaction unit is used by operators to input control instructions, view the real-time status of the system, and receive alarm information and fault prompts. The data storage unit is used to store sensor data, control instructions, work records, and alarm information throughout the entire hanging basket operation process. The data upload unit is used to synchronously upload construction data to the bridge construction management platform and the building information modeling system.

10. The intelligent walking and positioning control method for hanging baskets in bridge construction according to any one of claims 1-9, characterized in that, The method includes the following steps: Step 1: Initialize the pre-control, import the completed bridge alignment model, construct a digital twin that is bidirectionally mapped to the physical hanging basket, and complete the calibration of the sensor acquisition module and control parameters; Step 2: Safety interlock verification. Confirm that the walking anchor drive module is locked in place throughout the entire process, trigger the interlocking logic of the safety interlock protection module, and then verify the pre-tightening load distribution of the anchor decoupling and re-anchoring module. Step 3: Synchronous decoupling of the rear anchors. Start the rear anchor decoupling and re-anchoring module to complete the synchronous decoupling and full-process pressure holding of all rear anchor precision rolled threaded steel bars in one go. Step 4: Predictive synchronous walking. Based on the prediction results of the digital twin, the walking anchor drive module is driven to move forward step by step, maintaining at least one set of anchor locks throughout the process, and correcting synchronization deviations in real time. Step 5: Dynamic positioning under all working conditions. Through the servo fine-tuning compensation module, the posture of the hanging basket and the elevation of the bottom formwork are continuously fine-tuned during the movement. After reaching the position, dynamic compensation for the pouring deflection is completed. Step Six: In-place Re-anchor Locking. After the hanging basket is accurately positioned, the rear anchor decoupling and re-anchoring module is activated to complete the pre-anchoring and full anchoring locking, generating a full-process construction traceability report.

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