A span adaptive system and control method for intelligent beam yards

Abstract

This application relates to a span adaptive system and its control method for an intelligent beam yard. The system includes a platform, side formwork, formwork components, a quick-change mechanism for formwork, and a control and detection unit. The quick-change mechanism includes a positioning mechanism, a locking mechanism, and a T-junction quick-change interface located between the formwork and the platform and / or side formwork. The T-junction quick-change interface enables precise positioning, rapid locking and releasing of the formwork or side formwork, and high-speed transmission of sensor signals and control commands. It allows for rapid switching between mechanical and signal connections without tools, enabling flexible configuration and efficient replacement of formwork for concrete beams of different spans. The control method automatically selects matching formwork modules and side formwork combinations by collecting span and construction condition parameters, and performs coordinated control of the entire process, including quick-change of formwork, locking detection, digital twin pre-simulation, and collision detection. This achieves span adaptation of concrete beams, automation of the production process, and improved production efficiency.

Description

Technical Field

[0001] This application relates to the field of intelligent beam yard technology, and in particular to a span adaptive system and control method for an intelligent beam yard. Background Technology

[0002] Currently, precast concrete beam production lines generally adopt a core structure of fixed pedestals and specialized molds. For example, a dedicated production line primarily producing 32m box girders typically requires customized steel formwork (e.g., 4 sets of 32m outer molds and 4 sets of 32m inner molds), with each span beam type corresponding to an independent pedestal and formwork system. This production model has the advantage of high efficiency in the mass production of a single beam type, but it presents the following problems in engineering practice involving mixed production of multiple spans and beam types: On the one hand, most existing mainstream beam yards adopt non-standardized platform layouts, which are only suitable for specific spans or specific types of beams. For example, some prefabrication yards are only suitable for 40m T-beams. When it is necessary to switch to other spans such as 24m or 32m, production often needs to be stopped for dozens of hours or more to dismantle existing platforms, treat the foundations, rebuild new platforms, and replace the corresponding steel formwork. The process is cumbersome and time-consuming. This span switching method, which mainly relies on mechanical modification, is significantly different from the "efficient and flexible production" requirements proposed in the field of intelligent construction.

[0003] On the other hand, with the use of dedicated pedestals and templates, a large number of workstations are idle when the production span does not match the design span of the pedestals and templates. For example, a pedestal that is only compatible with 32m beams cannot be fully utilized when producing 24m beams, resulting in a high proportion of vacant workstations and a low overall equipment efficiency (OEE), making it difficult to realize the overall production capacity potential of the civil engineering site, pedestal steel structure, and electromechanical equipment. When critical equipment (such as tensioning jacks, tensioning pedestals, or curing equipment) fails, traditional production lines usually lack corresponding backup workstations or cross-line scheduling strategies, and the production rhythm is highly dependent on the normal operation of a single piece of equipment. Once critical equipment stops, the entire production line is often forced to shut down or significantly reduce production, lacking the ability to quickly restore capacity through flexible scheduling and process reconfiguration. Summary of the Invention

[0004] To address or partially address the problems existing in related technologies, this application provides a span adaptive system and control method for intelligent beam yards. Through movable platforms, quick-change templates, and hydraulic telescopic side molds combined with process package management, it achieves one-click switching and safe and efficient production of multiple spans and beam types.

[0005] The first aspect of this application provides a control method for a span adaptive system in an intelligent beam yard. The span adaptive system includes a main controller, a movable platform, a quick-change template mechanism, a hydraulic telescopic side formwork, and a tensioning device. The movable platform is equipped with a position sensor for detecting the platform's position and locking status. The quick-change template mechanism is equipped with an identification device for recognizing template information. The hydraulic telescopic side formwork is equipped with a positioning sensor for detecting the side formwork's positioning status. The tensioning device and the curing system are respectively equipped with a pressure sensor and an environmental sensor. The control method includes the following steps: Obtain the span switching command and target span information, call the process package corresponding to the target span information, and parse and pre-configure the control parameters in the process package. The control parameters include tension control parameters, curing control parameters and vibration control parameters. When the span switching command requires adjustment of the platform spacing, the movable platform is controlled to move along the track, and the platform spacing is adjusted according to the position signal fed back by the position sensor. When the platform spacing is detected to reach the predetermined range corresponding to the target span and the platform locking state meets the requirements, the platform movement is stopped and locked. When the movable platform is detected to be locked, the control template handling device will transport the template matching the target span to the corresponding platform position, and realize the docking of the template and the platform through the positioning mechanism and locking mechanism of the template quick change mechanism. The control and identification device identifies the template's model, span information, and / or cross-sectional information, and compares the identified template information with the process package information corresponding to the target span. When the template information matches the process package information, a template matching confirmation signal is output. When the template matching confirmation signal is received, the hydraulic telescopic side mold is controlled to extend and retract according to the cross-sectional parameters in the process package, and the side mold is determined to be in place based on the feedback signal of the position sensor. After confirming that the side mold extension and retraction adjustment is in place, a collision pre-simulation is performed based on the preset digital twin model. When the pre-simulation result is received, the hydraulic extension and retraction side mold is controlled to execute, and the maintenance parameters are activated before entering the production state.

[0006] When the template model, span information and / or cross-sectional information identified by the identification device are inconsistent with the process package information corresponding to the target span, the hydraulic telescopic side mold is prohibited from performing telescopic actions, the tensioning device is prohibited from entering the tensioning process, and a template mismatch alarm is issued on the central control interface.

[0007] The adjustment of the platform spacing based on the position signal fed back by the position sensor includes: Obtain the position of the movable platform and the positions of nearby devices fed back by the position sensor, and calculate the safe distance between the movable platform and nearby devices; When the safe distance is less than the first preset threshold, reduce the moving speed of the movable platform; When the safe distance is less than the second preset threshold, an emergency stop command is issued and the movable platform is stopped, and a collision warning is issued on the central control interface.

[0008] The digital twin model includes a movable platform, template, side molds, pouring and vibrating devices, tensioning devices, a curing system, and material flow paths. Collision simulation includes: The geometric position and status information of the digital twin model are updated based on real-time or near real-time data from position sensors, identification devices, and position sensors. The sequential drive of each device and component in the digital twin model executes corresponding movements, and collision detection is performed on its movement path. When geometric interference or movement logic conflict is detected, a pre-playback failure result is generated, and the interference position and process information are returned to the main controller.

[0009] The control method also includes the following steps: When a pre-rehearsal fails, the scheduling and optimization module is invoked to optimize and adjust the current span switching scheme. This includes replanning at least one of the following: platform allocation, workstation activation sequence, and key equipment operation time window. After outputting a new span switching scheme, the platform spacing adjustment, template handling and docking, side formwork extension and retraction adjustment, and digital twin pre-rehearsal steps are re-executed.

[0010] A span adaptive system for an intelligent beam yard, applicable to the control method of the span adaptive system for an intelligent beam yard as shown in the first aspect, includes a mechanical layer module, a control layer module, and a logic layer module; The mechanical layer module includes a movable platform, a quick-change template mechanism, a hydraulic telescopic side formwork, a pouring and vibration device, a tensioning device, and a curing system arranged in sequence. The movable platform is set on a track and can move along the track. The control layer module includes a main controller that is electrically connected to each device in the mechanical layer module, and a sensor network and a process package management module that are communicatively connected to the main controller. The main controller is used to receive span switching instructions, load the process package corresponding to the target span, and perform unified control of each device in the mechanical layer module based on the process package. The logic layer module includes a scheduling and optimization module that communicates with the main controller, as well as a digital twin and collision detection module.

[0011] In the mechanical layer module: The movable platform is equipped with a position sensor for detecting the platform's position and locking status; The quick-change formwork mechanism includes a positioning mechanism and a locking mechanism, which are used for quick docking and replacement between different spans or different types of formwork to achieve compatibility with various beam-type formwork. The quick-change formwork mechanism is equipped with an identification device for identifying formwork information, which is used to obtain the formwork model, span information and / or cross-sectional information. The hydraulic telescopic side formwork is adjusted in width and / or height by hydraulic drive to adapt to different beam cross sections, and the side formwork is equipped with positioning sensors to detect the positioning status of the side formwork. The pouring and vibration device is set in the side formwork area and is used to vibrate the beam during the concrete pouring process. The tensioning device is equipped with a pressure sensor to monitor the pressure or stress during the tensioning process; The maintenance system is equipped with environmental sensors to collect data on the temperature and / or humidity of the maintenance environment.

[0012] The template quick-change mechanism also includes a three-way quick-change interface for connecting the positioning mechanism and the locking mechanism. The three-way quick-change interface is set between the template and the platform and / or side mold, and integrates a conical positioning structure, a pneumatic locking mechanism and a communication transmission channel. The conical positioning structure is used to achieve precise docking of the template or side mold relative to the platform and / or side mold; the pneumatic locking mechanism is used to achieve rapid locking and releasing of the template or side mold relative to the platform and / or side mold; the communication transmission channel is used to achieve high-speed transmission of sensor signals and control commands, so that the template and / or side mold can quickly switch between mechanical connection and signal connection without tools.

[0013] The technical solution provided in this application may include the following beneficial effects: A span adaptive system and control method for an intelligent beam yard are disclosed. The system uses movable platforms arranged on the same track system, combined with a quick-change template mechanism and hydraulic telescopic side formwork. This allows for rapid adjustment of platform spacing, template type, and beam cross-sectional parameters without the need to dismantle and rebuild the platform foundation. This significantly shortens the switching time between different spans and beam types, improving production line flexibility. Through template recognition and a sensor network formed by multi-source sensors, along with unified process package management, key process parameters such as tensioning, curing, and vibration are centrally managed and automatically distributed at the system level. This reduces configuration errors caused by manual intervention and improves the overall safety, reliability, and fault tolerance of the system.

[0014] The method encapsulates control parameters for different spans and beam types into callable process packages, which are automatically parsed, distributed, and activated during switching, significantly reducing the error rate of process switching. Furthermore, it avoids template misuse and incorrect process execution through automatic identification and interlocking logic based on template information. Before the execution of critical processes, a real-time data-driven digital twin pre-simulation and collision detection are introduced to verify the rationality of the work path and operating conditions after span switching. If the pre-simulation fails or equipment malfunctions occur during actual operation, scheduling and optimization steps are automatically triggered to replan the allocation of workbenches, the sequence of workstation activation, and the time windows of critical equipment. This improves the flexibility, stability, and product quality consistency of the production line while ensuring safety.

[0015] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0016] The above and other objects, features and advantages of this application will become more apparent from the more detailed description of exemplary embodiments thereof in conjunction with the accompanying drawings, wherein the same reference numerals generally represent the same components in the exemplary embodiments thereof.

[0017] Figure 1 This is a schematic flowchart illustrating the span adaptive system control method in an embodiment of this application; Figure 2 This is a logical schematic diagram of the span adaptive system control method shown in the embodiments of this application; Figure 3 This is a schematic diagram of the overall architecture of the span adaptive system shown in the embodiments of this application; Figure 4 This is a schematic diagram of the structure of the three-way quick-change interface of the span adaptive system shown in the embodiments of this application. Detailed Implementation

[0018] Embodiments of this application will now be described in more detail with reference to the accompanying drawings. While embodiments of this application are shown in the drawings, it should be understood that this application may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to make this application more thorough and complete, and to fully convey the scope of this application to those skilled in the art.

[0019] It should be understood that although the terms "first," "second," "third," etc., may be used in this application to describe various information, this information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0020] In the description of this application, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0021] Unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0022] like Figure 1 , Figure 2 The diagram illustrates a control method for a span adaptive system in an intelligent beam yard. This method is applied to the span adaptive system of an intelligent beam yard, which includes a main controller, a movable platform, a quick-change formwork mechanism, hydraulic telescopic side formwork, and a tensioning device. The movable platform is equipped with position sensors for detecting its position and locking status. The quick-change formwork mechanism is equipped with an identification device for recognizing formwork information. The hydraulic telescopic side formwork is equipped with a positioning sensor for detecting its positioning status. Pressure sensors and environmental sensors are respectively installed on the tensioning device and the curing system. The control method includes the following steps: S1. Obtain the span switching command and target span information, call the process package corresponding to the target span information, and parse and pre-configure the control parameters in the process package. The control parameters include tension control parameters, curing control parameters and vibration control parameters.

[0023] S2. When the span switching command requires adjustment of the platform spacing, control the movable platform to move along the track and adjust the platform spacing according to the position signal fed back by the position sensor. When the platform spacing is detected to reach the predetermined range corresponding to the target span and the platform locking state meets the requirements, control to stop the platform movement and keep it locked.

[0024] Adjusting the platform spacing based on the position signal fed back from the position sensor includes: Obtain the position of the movable platform and the positions of nearby devices fed back by the position sensor, and calculate the safe distance between the movable platform and nearby devices; When the safe distance is less than the first preset threshold, reduce the moving speed of the movable platform; When the safe distance is less than the second preset threshold, an emergency stop command is issued and the movable platform is stopped, and a collision warning is issued on the central control interface.

[0025] S3. When the movable platform is detected to be locked, the control template handling device will transport the template matching the target span to the corresponding platform position, and realize the docking of the template and the platform through the positioning mechanism and locking mechanism of the template quick change mechanism.

[0026] S4. The control identification device identifies the template's model, span information, and / or cross-sectional information, and compares the identified template information with the process package information corresponding to the target span. When the template information matches the process package information, a template matching confirmation signal is output.

[0027] When the template model, span information and / or cross-sectional information identified by the identification device are inconsistent with the process package information corresponding to the target span, the hydraulic telescopic side mold is prohibited from performing telescopic actions, the tensioning device is prohibited from entering the tensioning process, and a template mismatch alarm is issued on the central control interface.

[0028] S5. When the template matching confirmation signal is obtained, control the hydraulic telescopic side mold to extend and retract according to the cross-sectional parameters in the process package, and determine whether the side mold is adjusted to the correct position based on the feedback signal of the position sensor.

[0029] S6. After confirming that the side mold extension and retraction adjustment is in place, a collision pre-simulation is performed based on the preset digital twin model. When the pre-simulation pass result is received, the hydraulic extension and retraction side mold is controlled to execute, and the maintenance parameters are activated before entering the production state.

[0030] The digital twin model includes a movable platform, template, side molds, pouring and vibrating devices, tensioning devices, curing system, and material flow path. Collision simulation includes: The geometric position and status information of the digital twin model are updated based on real-time or near real-time data from position sensors, identification devices, and position sensors. The sequential drive of each device and component in the digital twin model executes corresponding movements, and collision detection is performed on its movement path. When geometric interference or movement logic conflict is detected, a pre-playback failure result is generated, and the interference position and process information are returned to the main controller.

[0031] When a pre-rehearsal fails, the scheduling and optimization module is invoked to optimize and adjust the current span switching scheme. This includes replanning at least one of the following: platform allocation, workstation activation sequence, and key equipment operation time window. After outputting a new span switching scheme, the platform spacing adjustment, template handling and docking, side formwork extension and retraction adjustment, and digital twin pre-rehearsal steps are re-executed.

[0032] like Figure 3 The diagram illustrates a span adaptive system for an intelligent beam yard, and describes a control method applicable to span adaptive systems, comprising a mechanical layer module, a control layer module, and a logic layer module. The mechanical layer module includes a movable platform, a quick-change template mechanism, a hydraulic telescopic side formwork, a pouring and vibration device, a tensioning device, and a curing system arranged in sequence. The movable platform is set on a track and can move along the track.

[0033] The movable platform adopts a track-type moving structure, with foundation dimensions of 41m long × 3m clear width × 0.3m thick, and a foundation bearing capacity of ≥300kPa (fill compaction degree ≥96%, conforming to GB50007-2011). The platform spacing can be infinitely adjusted within the range of 24-40m via a servo motor, and the pre-camber is controlled within 2mm (to offset deflection under load). The maximum stress under concrete pouring conditions is 26.9kPa, and the deformation under tension conditions is 0.45mm, both of which meet the design requirements. The movable platform is equipped with position sensors for detecting the platform position and locking status.

[0034] The quick-change formwork mechanism is equipped with an identification device for recognizing formwork information, including the formwork model, span, and / or cross-sectional information. The mechanism includes a positioning mechanism and a locking mechanism for rapid docking and replacement between formwork of different spans or types, achieving compatibility with various beam-type formwork. It also includes a T-junction quick-change interface for connecting the positioning and locking mechanisms. The T-junction quick-change interface is as follows: Figure 4As shown, an integrated conical positioning structure, pneumatic locking mechanism, and communication transmission channel are installed between the template and the pedestal and / or side mold. The conical positioning structure is used to achieve precise docking of the template or side mold relative to the pedestal and / or side mold; the pneumatic locking mechanism is used to achieve rapid locking and releasing of the template or side mold relative to the pedestal and / or side mold; the communication transmission channel is used to achieve high-speed transmission of sensor signals and control commands, so that the template and / or side mold can quickly switch between mechanical connection and signal connection without tools. Switching efficiency: toolless docking time ≤ 3 minutes, compatible with 24 / 32 / 40m beam templates, docking error ≤ 0.5mm.

[0035] The hydraulic telescopic side formwork is hydraulically driven to adjust the width and / or height of the side formwork to adapt to different beam cross-sections. The side formwork is equipped with a positioning sensor to detect the positioning status of the side formwork. The telescopic range is 2.4-4.0m wide (adapting to different beam cross-sections) through the hydraulic cylinder of the side formwork panel. It is equipped with an integrated 2.2KW attached vibrator with an adjustable vibration frequency of 50-100Hz.

[0036] The pouring and vibration device is set in the side formwork area to vibrate the beam during the concrete pouring process; the tensioning device is equipped with a pressure sensor to monitor the pressure or stress during the tensioning process; the curing system is equipped with an environmental sensor to collect the temperature and / or humidity of the curing environment.

[0037] The control layer module includes a main controller that is electrically connected to each device in the mechanical layer module, and a sensor network and a process package management module that are communicatively connected to the main controller. The main controller is used to receive span switching instructions, load the process package corresponding to the target span, and perform unified control of each device in the mechanical layer module based on the process package.

[0038] The main controller uses a Siemens S7-1500 PLC (supporting WebAssembly virtual machine) and is equipped with a 16-channel analog input module (AI8×13bit); the sensor network deploys pressure sensors, temperature and humidity sensors, and laser positioning sensors. (1) Pressure sensor (equipped with intelligent tensioning machine): arranged in the hydraulic pipeline and anchoring end of the tensioning jack, used to monitor the hydraulic pressure value in real time during the tensioning process and convert it into tension stress (accuracy ±1%).

[0039] The system employs closed-loop feedback control. It compares real-time collected pressure data with the preset tension stress-time curve in the process package, dynamically adjusting the hydraulic system output using a PID algorithm to ensure the tensioning process meets design requirements. Simultaneously, pressure data is displayed in real-time on the central control interface for management review and intervention. Data is also synchronously uploaded to a digital twin system for virtual tensioning process simulation and historical data tracing.

[0040] (2) Temperature and humidity sensors: placed inside the curing shed, on the surface of the beam and at key sections, to collect the temperature (accuracy ±0.5℃) and relative humidity of the curing environment in real time.

[0041] The system dynamically adjusts the curing curve (such as steam curing time and temperature gradient) based on real-time temperature and humidity data to achieve "adaptive curing." The data is used for subsequent quality traceability and process optimization, and supports the correction of concrete strength development models.

[0042] (3) Laser positioning sensors: installed on both sides and ends of the movable platform track, with no less than 4 measuring points on each platform, for real-time monitoring of the platform's position coordinates on the track: 1) Position confirmation: During the adjustment of the platform spacing, the laser sensor provides real-time feedback on the position information. When the platform moves to the target position (such as a 24m span), the system automatically determines that it is "in position" and sends a locking command.

[0043] 2) Closed-loop control: Combined with the servo motor encoder, a dual closed-loop control of "position-speed" is formed to ensure smooth movement and accurate positioning.

[0044] 3) Collision avoidance warning: Real-time monitoring of the distance to adjacent equipment (such as concrete placing machine, AGV) during movement, triggering warning or emergency stop.

[0045] The process package is packaged as follows: the tension pressure, curing curve, vibration parameters, etc. of beams with different spans are packaged into WebAssembly modules; the memory data copying and loading time is ≤2 minutes, and it is compatible with BIM component library parameters (such as IFC standard modules).

[0046] The basic steps for mapping process package parameters to control channels: The system reads the JSON / XML format parameter file in the process package and extracts process parameters such as tension pressure curve, curing temperature curve, and vibration frequency. The tensioning pressure curve is bound to the analog output module (AO) of the corresponding tensioning jack, the curing temperature curve is bound to the curing system temperature control module (PID controller), and the vibration parameters are bound to the vibrator frequency controller. The parameters are sent to each execution device in real time via the Profinet bus and written to the device registers. After the equipment feedback parameters are received and confirmed, the system marks the process package as "activated" and allows the corresponding process to be executed.

[0047] The equipment linkage protocol uses Profinet bus to achieve real-time communication between AGV (load capacity 50t), hydraulic system and concrete placing boom (arm length 18m), with a response delay ≤50ms.

[0048] Interlocking logic between AGV, hydraulic system, and concrete placing boom: Only after the laser sensor confirms that the platform is in place and mechanically locked can the AGV enter the station to transport the template. Only after the RFID reads the template tag information and matches it with the process package can the hydraulic system allow the side mold extension and retraction to be executed.

[0049] System restrictions: If the platform is not locked in place, the central control interface will display "Platform not in place" and the fabric placing machine will be prohibited from starting; if the collision detection fails, the system will lock all critical equipment and issue an alarm indicating "Interference risk".

[0050] The logic layer module includes a scheduling and optimization module that communicates with the main controller, as well as a digital twin and collision detection module. It is based on a dynamic scheduling genetic algorithm, with the following formula: in, This represents the total replacement time. To improve the overall utilization rate of equipment, Penalty costs for idle workstations , , This is a weighting coefficient that is dynamically adjusted based on production priority.

[0051] The constraints are: platform movement range: 24m≤L≤40m, equipment response delay: ≤50ms, and capacity retention rate: ≥85%.

[0052] Optimization objective: Maximize equipment utilization and minimize changeover time; population size: 50; number of iterations: 30; crossover probability: 0.7. Fault Response: For single-point faults (such as vibrator failure), generate a process redistribution plan within 10 seconds and schedule a backup workstation to take over the task.

[0053] The digital twin model is a BIM+GIS digital twin system, covering all elements of "people, machines, materials, methods, and environment," integrating 3D models of the platform, templates, and equipment. The inspection objects include all moving equipment and structures such as the platform, side molds, inner molds, concrete placing boom, AGVs, and gantry cranes. The pre-simulation function, based on real-time IoT data (platform position, side mold status), completes the simulation of the entire pouring and tensioning process within 5 minutes, with a collision detection accuracy of 0.1mm.

[0054] The detection of digital twin models includes: BIM+GIS-based bounding box detection generates an axial bounding box (AABB) for each moving component and calculates its spatial position and orientation in real time. Multi-frame positions are interpolated along the motion path, and continuous collision detection (CCD) predicts potential collisions. The detection resolution is set to 0.1mm, supporting penetration detection and gap warning.

[0055] If a collision is detected, it is marked as "interference," the system prohibits the next action, and the collision area is highlighted in the twin model; if no collision is detected, it is marked as "pass," allowing the process to proceed to the next step. Virtual debugging of template parameters and visualized monitoring of production progress are supported (refer to the Baohui Beam Yard Intelligent Control Center solution).

[0056] A dual-span switching verification embodiment: Switching between 1.32m and 24m box girders (total time: 85 minutes) Trigger: The central platform receives the bridge erection plan and analyzes the span switching requirements; Mechanical reconfiguration: AGV transports 24m side mold (15min) → quick-change interface docking (3min) → platform spacing adjustment (20min); Control switching: PLC loads 24m process package (2min) → bus synchronization parameters; Pre-production simulation: Digital twin collision detection (5 min) → Hydraulic side mold extension and retraction in place (25 min) → Activation of maintenance parameters (15 min).

[0057] 1. Command Triggering Phase Triggering method: Active triggering. The production scheduler enters the "span switching command" in the central control system interface, selects the target span (24m), and the system automatically parses the process package requirements.

[0058] The instructions include the target span, beam type, process package version, and estimated changeover time.

[0059] 2. Mechanical Reconfiguration Stage Step sequence: AGV transport template: The AGV retrieves a 24m side template from the template library and transports it to the target platform workstation.

[0060] Adjustment of pedestal spacing: The PLC sends a movement command, and the servo motor drives the platform to move along the track.

[0061] The laser positioning sensor provides real-time position feedback, and closed-loop control ensures movement up to a 24m span (error ≤1mm).

[0062] Once in position, the mechanical locking device automatically locks.

[0063] Quick-switch interface integration: The AGV pushes the template into the quick-change interface, and the tapered positioning pin automatically aligns.

[0064] The pneumatic locking device is activated, and the EtherCAT interface completes the electrical and data connection.

[0065] Hydraulic side mold extension: The hydraulic cylinder drives the side mold panel to shrink from 32m to 24m in width.

[0066] The system detects the side mold positioning signal and confirms the locked state.

[0067] 3. Control switching phase Process package loading: The PLC loads the 24m beam process package (WebAssembly module) from the server, and the memory copying time is ≤2min.

[0068] Parameter mapping: The tension curve is sent to the tension controller.

[0069] The maintenance curve is sent to the temperature control system.

[0070] The vibration parameters are sent to the vibrator controller.

[0071] Bus synchronization: Profinet bus synchronizes all device parameters with a response latency of ≤50ms.

[0072] 4. Preliminary Collision Detection Phase Process description: The digital twin system loads real-time IoT data (base position, side model status, and device posture).

[0073] The system simulates the entire process of "pouring → vibration → tensioning → curing" in a virtual environment.

[0074] The collision detection engine checks frame by frame whether the device's motion path interferes with the collision detection.

[0075] Basis for judgment: Passing conditions: No collision alarms throughout the process, and the movement trajectories of each device conform to the process logic.

[0076] Failure condition: A collision or logical conflict is detected. The system will display "Preview failed" and provide modification suggestions.

[0077] Result of this example: The rehearsal passed.

[0078] 5. Activation and commissioning of maintenance parameters Activation purpose: To write the maintenance curve parameters into the maintenance controller and start environmental monitoring.

[0079] Activation effect: The system dynamically adjusts the maintenance strategy based on real-time temperature and humidity data.

[0080] Data is continuously collected during the maintenance process for quality traceability and process optimization.

[0081] Final state: The system marks the workstation as "ready" and allows pouring to begin.

[0082] The central control interface displays "Span switching complete, ready for production". Finally, it should be noted that in this document, relationships such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "include," "contain," or any other variations are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0083] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0084] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0085] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application.

[0086] The various embodiments of this application have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A control method for a span adaptive system of an intelligent beam yard, characterized in that, A span adaptive system for intelligent beam yards includes a main controller, a movable platform, a quick-change formwork mechanism, hydraulic telescopic side forms, and a tensioning device. The movable platform is equipped with position sensors for detecting its position and locking status. The quick-change formwork mechanism is equipped with an identification device for recognizing formwork information. The hydraulic telescopic side forms are equipped with position sensors for detecting their positioning status. The tensioning device and the curing system are respectively equipped with pressure sensors and environmental sensors. The control method includes the following steps: Obtain the span switching command and target span information, call the process package corresponding to the target span information, and parse and pre-configure the control parameters in the process package. The control parameters include tension control parameters, curing control parameters and vibration control parameters. When it is determined that the span switching command requires adjustment of the platform spacing, the movable platform is controlled to move along the track, and the platform spacing is adjusted according to the position signal fed back by the position sensor. When it is detected that the platform spacing reaches the predetermined range corresponding to the target span and the platform locking state meets the requirements, the platform movement is stopped and locked. When the movable platform is detected to be locked, the control template handling device will transport the template matching the target span to the corresponding platform position, and the template will be docked with the platform through the positioning mechanism and locking mechanism of the template quick change mechanism. The identification device is controlled to identify the template's model, span information, and / or cross-sectional information, and compare the identified template information with the process package information corresponding to the target span. When the template information matches the process package information, a template matching confirmation signal is output. When a template matching confirmation signal is received, the hydraulic telescopic side mold is controlled to extend and retract according to the cross-sectional parameters in the process package, and the side mold is determined to be in place based on the feedback signal of the positioning sensor. After confirming that the side mold extension and retraction adjustment is in place, a collision pre-simulation is performed based on a preset digital twin model. When the pre-simulation result is received, the hydraulic extension and retraction side mold is controlled to execute, and the maintenance parameters are activated before entering the production state.

2. The control method for the span adaptive system of the intelligent beam yard according to claim 1, characterized in that, When the template model, span information and / or cross-sectional information identified by the identification device are inconsistent with the process package information corresponding to the target span, the hydraulic telescopic side mold is prohibited from performing telescopic actions, the tensioning device is prohibited from entering the tensioning process, and a template mismatch alarm is issued on the central control interface.

3. The control method for the span adaptive system of the intelligent beam yard according to claim 1, characterized in that, The step of adjusting the platform spacing based on the position signal fed back by the position sensor includes: The position of the movable platform and the position of the adjacent devices fed back by the position sensor are obtained, and the safe distance between the movable platform and the adjacent devices is calculated. When the safe distance is less than a first preset threshold, the moving speed of the movable platform is reduced. When the safe distance is less than the second preset threshold, an emergency stop command is issued and the movable platform is stopped from moving, and an anti-collision alarm is issued on the central control interface.

4. The control method for the span adaptive system of the intelligent beam yard according to claim 1, characterized in that, The digital twin model includes a movable platform, template, side molds, pouring and vibrating devices, tensioning devices, a curing system, and material flow paths. The collision simulation includes: The geometric position and status information of the digital twin model are updated based on the real-time or near-real-time data from the position sensor, identification device, and positioning sensor. The system sequentially drives each device and component in the digital twin model to perform corresponding movements and performs collision detection on their movement paths. When geometric interference or movement logic conflict is detected, a pre-playback failure result is generated, and the interference position and process information are returned to the main controller.

5. The control method for the span adaptive system of the intelligent beam yard according to claim 4, characterized in that, The control method further includes the following steps: When the pre-rehearsal fails, the scheduling and optimization module is invoked to optimize and adjust the current span switching scheme. This includes replanning at least one of the following: platform allocation, workstation activation sequence, and key equipment operation time window. After outputting a new span switching scheme, the platform spacing adjustment, template handling and docking, side mold extension and retraction adjustment, and digital twin pre-rehearsal steps are re-executed.

6. A span adaptive system for an intelligent beam yard, applicable to the control method of the span adaptive system for an intelligent beam yard as described in any one of claims 1-5, characterized in that, It includes a mechanical layer module, a control layer module, and a logic layer module; The mechanical layer module includes a movable platform, a quick-change template mechanism, a hydraulic telescopic side formwork, a pouring and vibration device, a tensioning device, and a curing system arranged in sequence. The movable platform is set on a track and can move along the track. The control layer module includes a main controller electrically connected to each device in the mechanical layer module, and a sensor network and a process package management module communicatively connected to the main controller. The main controller is used to receive span switching instructions, load the process package corresponding to the target span, and perform unified control of each device in the mechanical layer module based on the process package. The logic layer module includes a scheduling and optimization module and a digital twin and collision detection module that are communicatively connected to the main controller.

7. The span adaptive system for intelligent beam yards according to claim 6, characterized in that, In the mechanical layer module: The movable platform is equipped with a position sensor for detecting the platform's position and locking status. The quick-change template mechanism includes a positioning mechanism and a locking mechanism, which are used for quick docking and replacement between templates of different spans or different types to achieve compatibility of various beam templates. The quick-change template mechanism is equipped with an identification device for identifying template information, which is used to obtain the template model, span information and / or cross-sectional information. The hydraulic telescopic side mold is adjusted in width and / or height by hydraulic drive to adapt to different beam cross sections, and the side mold is equipped with a positioning sensor for detecting the positioning status of the side mold; The pouring and vibration device is installed in the side formwork area and is used to vibrate the beam during the concrete pouring process. The tensioning device is equipped with a pressure sensor to monitor the pressure or stress during the tensioning process; The maintenance system is equipped with environmental sensors to collect the temperature and / or humidity of the maintenance environment.

8. The span adaptive system for intelligent beam yards according to claim 7, characterized in that, The template quick-change mechanism also includes a three-way quick-change interface for connecting the positioning mechanism and the locking mechanism. The three-way quick-change interface is located between the template and the base and / or the side mold, and integrates a conical positioning structure, a pneumatic locking mechanism, and a communication transmission channel. The conical positioning structure is used to achieve precise docking of the template or side mold relative to the base and / or the side mold. The pneumatic locking mechanism is used to achieve rapid locking and releasing of the template or side mold relative to the base and / or the side mold. The communication transmission channel is used to achieve high-speed transmission of sensor signals and control commands, so that the template and / or the side mold can quickly switch between mechanical connection and signal connection without tools.

Images