Three-dimensional alignment fine adjustment and rapid installation tool for assembled guardrails and use method thereof

Abstract

The application relates to the technical field of bridge and road guardrail construction, in particular to a three-dimensional alignment fine adjustment and rapid installation tool for an assembled guardrail and a use method thereof. The tool comprises a base, a longitudinal adjusting mechanism, a transverse adjusting mechanism and a height adjusting mechanism. The base is connected with a forklift through a plug-in groove; the longitudinal mechanism drives a bearing platform to move along a guide rail by using a servo motor; the transverse and height mechanisms respectively adjust the corresponding dimensions of the hoisted assembled guardrail by using a horizontal transmission machine and a vertical elevator, and the device is integrated with a displacement sensor. The use method of the tool utilizes a double-speed frequency conversion assembly and an accuracy compensation control module of a controller, receives displacement feedback of the displacement sensor, calculates a deviation vector, drives an executing mechanism to reversely compensate displacement, and realizes accurate control of multi-dimensional adjustment. The application satisfies millimeter-level accurate control during installation of the assembled guardrail, eliminates multi-dimensional adjustment interference, and significantly improves the accuracy and construction safety of the assembled guardrail installation.

Description

Technical Field

[0001] This invention relates to the field of bridge and road guardrail construction technology, specifically to a prefabricated guardrail three-dimensional alignment and fine adjustment and rapid installation tool and its usage method. Background Technology

[0002] With the promotion of prefabricated construction, prefabricated guardrails have begun to be introduced into bridge construction as auxiliary structures on both sides of bridges. Their overall integrity and smooth lines after installation not only determine the overall aesthetic appearance of the bridge but also play a crucial role in its crashworthiness under extreme impacts after the bridge opens to traffic. Therefore, the installation effect and quality of prefabricated guardrails are of paramount importance.

[0003] In current prefabricated guardrail installation operations, the operation and on-site positioning of prefabricated guardrails typically rely on heavy lifting machinery such as forklifts, truck cranes, or specialized gantry cranes. These devices, equipped with hydraulic systems and other power units, provide powerful lifting and lateral movement capabilities, essentially meeting the requirements for rapid power output under heavy loads and long strokes. This effectively solves the problems of vertical handling and horizontal transport of large-tonnage prefabricated guardrails, demonstrating extremely high operational efficiency and environmental adaptability in handling and stacking scenarios.

[0004] However, during the final installation and positioning of prefabricated guardrails, finer adjustments are often required after the guardrails are lifted. Traditional heavy machinery's extensive output is ill-suited for this. For example, when installing prefabricated guardrails using a forklift, the guardrail is suspended from the forklift forks, and its position is adjusted by operating the forklift. However, due to the lack of precise control in forklifts, over-adjustment often occurs when the guardrail is lifted, requiring extensive operator experience or multiple adjustments to effectively control its position. Furthermore, in multi-dimensional adjustment scenarios, the equipment often lacks a reliable self-locking mechanism for a single adjustment dimension. Attempts to make minor corrections to the lifted object inevitably induce displacement in other directions. This multi-dimensional mutual interference characteristic often leads to a cycle of repeated corrections during on-site installation of guardrails, where adjusting the longitudinal direction affects the lateral or height direction. This requires additional operators and auxiliary tools to perform real-time positioning measurements and position adjustments, which greatly reduces construction efficiency. Furthermore, workers adjusting heavy loads at close range near the edge of the bridge are highly susceptible to being squeezed due to the imbalance or inertia of the load, posing a certain safety risk to construction workers working in the air.

[0005] In summary, in the context of prefabricated guardrail construction, there is an urgent need in this field for a tooling that can provide precise adjustments and ensures that multi-dimensional fine-tuning does not interfere with each other during prefabricated guardrail installation. Summary of the Invention

[0006] This invention provides a three-dimensional alignment and fine-tuning fixture and a rapid installation method for prefabricated guardrails, which solves the problems of limited adjustment accuracy, mutual interference between multi-dimensional adjustments, high degree of manual intervention, and strong dependence on the micro-operation of heavy lifting machinery in the installation and positioning process of prefabricated guardrails.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A prefabricated guardrail three-dimensional alignment and fine adjustment and rapid installation fixture includes a base, a longitudinal adjustment mechanism disposed on the base, a lateral adjustment mechanism disposed on the longitudinal adjustment mechanism, a height adjustment mechanism connected to the lateral adjustment mechanism, and a controller disposed on the base.

[0008] The base serves as the basic load-bearing component of the entire tooling. It has a slot on the side for forklift forks to enter, and a sliding groove in the middle along the longitudinal direction of the bridge. The sliding groove is equipped with a guide rail on its side wall. The longitudinal adjustment mechanism is disposed in the sliding groove and includes a support platform installed on the guide rail and capable of reciprocating along it, a servo motor for driving the displacement of the support platform, and a first displacement sensor for monitoring the longitudinal displacement of the support platform. A lateral adjustment mechanism is provided above the pier and includes at least two guide grooves fixedly installed on the pier, a horizontal transmission machine arranged in the guide grooves along the transverse direction of the bridge, and a second displacement sensor for monitoring the transmission displacement of the horizontal transmission machine. The height adjustment mechanism is vertically connected to the transmission output end of the horizontal transmission machine, and includes a vertical lifting machine for vertical lifting and a lifting device set at the bottom of the vertical lifting machine; The controller is electrically connected to the servo motor, the horizontal transmission machine, the vertical lifting machine, the first displacement sensor, and the second displacement sensor, respectively. The controller integrates a precision compensation control module, which is used to perform real-time reverse compensation for the displacement deviation generated by the adjustment mechanism in the non-adjustment dimension based on the feedback data of the displacement sensor.

[0009] Furthermore, the base has several through pin holes at the corresponding positions of the insertion slots, and pins are provided in the pin holes for locking and fixing when the forks are inserted into the insertion slots.

[0010] Furthermore, the longitudinal adjustment mechanism also includes a bearing wheel assembly, a screw, and a nut seat; the bearing wheel assembly is installed at the bottom of the platform and rolls in cooperation with the guide rail; the output shaft of the servo motor is connected to the screw, the nut seat is fixed at the bottom of the sliding groove, the screw is screwed to the nut seat, and the servo motor drives the screw to rotate, thereby driving the platform to generate longitudinal displacement.

[0011] Furthermore, a positioning wheel is provided on the outer periphery of the output end of the horizontal transmission machine, and a positioning groove matching the positioning wheel is opened on the inner surface of the side wall of the guide groove. The positioning wheel rolls in the positioning groove to provide horizontal support for the transmission output end of the horizontal transmission machine.

[0012] Furthermore, the power input terminals of the servo motor, horizontal transmission, and vertical lifting platform are all connected to a dual-speed frequency converter. The dual-speed frequency converter is controlled by the controller and is used to switch between a coarse adjustment mode in which the servo motor, horizontal transmission, and vertical lifting platform operate at a first speed or a fine adjustment mode in which they operate at a second speed, and the first speed is greater than the second speed.

[0013] Furthermore, the horizontal transmission machine is a first hydraulic press, and the vertical lifting machine is a second hydraulic press. The hydraulic cylinder of the second hydraulic press is vertically connected to the piston end of the first hydraulic press, and the piston end of the second hydraulic press is connected to the lifting device.

[0014] Furthermore, the horizontal transmission machine includes a first worm gear seat fixed on the support platform, a transverse transmission screw screw screwed into the first worm gear seat, and a first motor driving the transverse transmission screw; the vertical lifting machine includes a second worm gear seat connected to the end of the transverse transmission screw, a lifting screw screw screwed into the second worm gear seat, and a second motor driving the lifting screw.

[0015] The present invention also provides a method for using the above-mentioned tooling, the specific steps of which are as follows: Step S1, Equipment fixing: Insert the forklift forks into the insertion slot of the tooling, and lock the base and forks together with the pins; Step S2, component transfer: The prefabricated guardrail is lifted to the installation position using a lifting device, and a distance sensor facing the bridge surface is installed at the bottom of the guardrail; Step S3, coarse adjustment positioning: The controller drives the dual-speed frequency converter to enter the coarse adjustment mode, and coordinates the various adjustment mechanisms to make the guardrail quickly approach the installation posture. Step S4, fine-tuning compensation: When the data fed back by the distance sensor reaches the preset value, the controller drives the dual-speed frequency converter to switch to fine-tuning mode, and performs fine-tuning in the longitudinal and lateral dimensions in sequence. After the guardrail reaches the preset installation position in the corresponding dimension, the displacement data of the first displacement sensor and the second displacement sensor are recorded at this time. Then, fine-tuning in the height dimension is performed. During this period, the precision compensation control module obtains the deviation data of the first and second displacement sensors in real time and drives the servo motor or horizontal transmission to perform reverse displacement compensation until the displacement data is reset.

[0016] Furthermore, the specific execution logic of the precision compensation control process described in step S4 is as follows: If the first displacement sensor or the second displacement sensor detects a change in displacement data, the controller calculates the vector difference between the current displacement data and the recorded displacement data in real time, and sends a control pulse to the power end of the servo motor or horizontal transmission as a compensation amount to drive it to adjust in the opposite direction to offset the error generated by the mechanical linkage.

[0017] Furthermore, step S1 includes installing pressure sensors on the lifting devices to acquire load data of each lifting device carrying the guardrail in real time during the guardrail installation construction; steps S3 and S4 include monitoring the load status of the lifting devices. When the load data of each lifting device is unbalanced and the difference exceeds the preset safety threshold, the controller immediately stops and locks all adjustment mechanisms; then, manual intervention is used to check each component, adjust the guardrail lifting status, and after confirming that the load difference has returned to the safety threshold, the machine is restarted to continue the installation work.

[0018] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention discloses a three-dimensional alignment and fine-tuning fixture for prefabricated guardrails, enabling rapid installation. By integrating three independent and mutually perpendicular mechanical adjustment mechanisms (longitudinal, transverse, and height) on the fixture's base, it changes the traditional, crude method of relying on forklifts and other lifting machinery to adjust the position of the prefabricated guardrail. During installation, only the lifting machinery is used as a coarse positioning carrier, while the fixture serves as the posture adjustment tool. This effectively solves the problem of imprecise hydraulic control of heavy equipment, improving the alignment accuracy of the guardrail from centimeter-level to millimeter-level. It avoids the repeated adjustments during installation and the reliance on forklift drivers' micro-management skills. Using this fixture, construction personnel only need to remotely locate and confirm the installation posture of the guardrail using surveying equipment, reducing the number of times workers need to intervene in high-altitude construction scenarios and improving construction safety.

[0019] 2. During the installation of guardrails, this invention utilizes the fusion technology of the controller and multiple sensors within the tooling to achieve intelligent control of multi-dimensional adjustments during the installation of prefabricated guardrails. On one hand, in the actual operation of guardrail installation in existing technologies, single-dimensional movement of the guardrail posture often causes linkage errors in other dimensions due to mechanical clearances or center of gravity shifts. This invention uses displacement sensors to capture these minute deviations in real time, monitors displacement fluctuations in non-adjustable dimensions in real time, and performs active strain compensation. This avoids the drawbacks of repeated cyclic adjustments or corrections in the longitudinal, transverse, and height directions in complex installation environments, significantly improving construction efficiency. Furthermore, the introduction of a dual-speed frequency conversion component in the equipment improves posture adjustment efficiency during coarse adjustments, enabling the guardrail to be quickly positioned. During fine adjustments, the adjustment speed can be reduced to further improve posture adjustment accuracy, significantly reducing inertial impact during the adjustment process and improving the linear quality of the prefabricated guardrail installation operation.

[0020] 3. In one embodiment of the present invention, a combination of a worm gear transmission pair and a worm gear lifting pair is used. These mechanical transmission structures have good rigidity and physical self-locking characteristics. In the event of a power outage, the current position can be locked by mechanical friction, preventing displacement drift of large-tonnage guardrails due to gravity or inertia during adjustment, thus structurally ensuring the stability and safety of the adjustment process.

[0021] In summary, this invention, through precise mechanical transmission coordination, multi-dimensional control logic, and a closed-loop sensor feedback system, constructs a high-precision and high-stability prefabricated guardrail installation assistance method, which significantly improves the construction quality and efficiency of bridge auxiliary structures. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the tooling of the present invention; Figure 2 This is a bottom view schematic diagram of the overall tooling structure of the present invention; Figure 3 This is a disassembly diagram of the various adjustment mechanisms of the tooling of the present invention; Figure 4 This is a bottom view of the tooling support platform of the present invention; Figure 5 This is a schematic diagram of the connection control logic of the controller in the tooling of the present invention; Figure 6 This is a schematic diagram of an embodiment of the present invention in the installation operation state.

[0023] In the attached diagram: 1. Base; 11. Insertion slot; 12. Sliding slot; 13. Guide rail; 14. Pin hole; 15. Pin; 2. Longitudinal adjustment mechanism; 21. Support platform; 22. Bearing wheel set; 23. Screw; 24. Nut seat; 25. Servo motor; 3. Lateral adjustment mechanism; 31. First hydraulic press; 32. Guide groove; 33. Positioning wheel; 34. Positioning groove; 4. Height adjustment mechanism; 41. Second hydraulic press; 5. Lifting device; 6. Forks; 7. Prefabricated guardrail; 8. Controller. Detailed Implementation

[0024] The technical solution of the present invention will now be described with reference to the accompanying drawings. However, the described embodiments are only some embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0025] It should be noted that in the description of this invention, the terms "upper", "lower", "horizontal", "longitudinal", etc., which indicate the direction or positional relationship, are based on the direction or positional relationship shown in the drawings. For example, "horizontal" refers to the lateral span direction of the bridge, and "longitudinal" refers to the longitudinal length direction of the bridge. This is only for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0026] In the description of this invention, unless otherwise explicitly specified and limited, the terms "set", "install", "connect", and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to an electrical connection or a mechanical connection; they can refer to an indirect connection through an intermediate medium, or they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention in conjunction with the specific circumstances.

[0027] The accompanying drawings show various structural schematic diagrams according to embodiments disclosed in the present invention. These drawings are not drawn to scale, and some details may be enlarged or omitted for illustrative purposes.

[0028] like Figure 1-6As shown, this invention provides a three-dimensional alignment and rapid installation fixture for prefabricated guardrails, primarily used for precise alignment of the ends of precast concrete guardrails during bridge construction. It includes a base, a longitudinal adjustment mechanism mounted on the base, a lateral adjustment mechanism mounted on the longitudinal adjustment mechanism, a height adjustment mechanism connected to the lateral adjustment mechanism, and a controller 8 mounted on the base. In actual bridge engineering, prefabricated guardrails are bulky and heavy. Traditional hoisting equipment often only achieves rough positioning at the centimeter level, while the guardrail's alignment requirements typically need to reach the millimeter level. This invention uses a precise mechanical structure to independently adjust and control the horizontal, longitudinal, and height dimensions of the guardrail during installation, effectively improving the accuracy of the prefabricated guardrail's posture control at the installation end.

[0029] Specifically, the core load-bearing component of this device is the base 1. The base 1 is constructed entirely of high-strength welded steel, possessing sufficient rigidity to support the assembled guardrail 7, which weighs several tons. Two horizontally arranged insertion slots 11 are provided on the side of the base 1. The cross-sectional shape of the insertion slots 11 is designed to match the shape of the standard forklift forks 6. To prevent the base 1 from detaching from the forks 6 during operation, several through pin holes 14 are pre-drilled on the base 1 corresponding to the insertion slots 11. After the forklift forks 6 are fully inserted into the insertion slots 11, the operator inserts pins 15 through the pin holes 14. The mechanical locking of the pins 15 firmly secures the forks 6 within the insertion slots 11.

[0030] A sliding groove 12 is formed longitudinally in the middle of the base 1 (consistent with the longitudinal direction of the bridge when the forklift is facing the guardrail installation position, the same below). Guide rails 13 extending longitudinally are symmetrically installed on the inner walls of both sides of the sliding groove 12. A longitudinal adjustment mechanism 2 is installed inside the sliding groove 12, including a support platform 21, a load-bearing wheel set 22, and a servo motor 25; the load-bearing wheel set 22 is located at the bottom of the support platform 21 and forms a rolling engagement with the guide rails 13. The servo motor 25 is fixed to the bottom of the support platform 21, and the servo motor 25 drives the support platform to perform reciprocating linear displacement along the guide rails on the longitudinal axis or to perform static displacement locking through mechanical transmission. Specifically, the output shaft of the servo motor 25 is connected to a screw 23, and a nut seat 24 with internal threads is fixed at the bottom of the sliding groove 12. The screw 23 and the servo motor 25 are located on the support platform 21, and the screw 23 and the nut seat 24 are screwed together. When the servo motor 25 receives the drive command to rotate, since the nut seat 24 is fixed, the rotational motion of the screw 23 is converted into the longitudinal thrust of the support 21 along the guide rail 13.

[0031] The lateral adjustment mechanism 3 is located above the pier 21 and is used to control the displacement of the guardrail in the direction perpendicular to the bridge centerline (i.e., the transverse direction). The lateral adjustment mechanism 3 includes at least two guide grooves 32 arranged in parallel above the pier 21, and a horizontal transmission mechanism installed in the guide grooves 32. The power input end of the horizontal transmission mechanism is fixed to the pier 21 by bolts, and its running axis is perpendicular to the axis of the sliding groove 12 of the base 1. To ensure the stability of lateral movement and prevent the horizontal transmission output end from forming a cantilever state and causing mechanical downward deflection during lateral extension, a positioning wheel 33 is provided on the side wall near the connection node with the height adjustment mechanism at the power transmission output end of the horizontal transmission. A positioning groove 34 matching the outer diameter of the positioning wheel 33 is formed on the inner surface of the side wall of the guide groove 32. The positioning wheel 33 is embedded in the positioning groove 34 and can roll along the positioning groove 34, providing balanced support for the movement of the power transmission output end of the horizontal transmission, ensuring the straightness of lateral adjustment, and preventing additional downward deflection deformation caused by the cantilever state of the end of the horizontal transmission due to pushing, which would affect the adjustment accuracy.

[0032] The height adjustment mechanism 4 is connected to the end of the horizontal adjustment mechanism 3 and is responsible for raising and lowering the guardrail in the vertical direction. The height adjustment mechanism 4 mainly consists of a vertical lift and a hoisting device 5 installed at its bottom. The fixed end of the vertical lift is vertically connected to the power output end of the horizontal transmission mechanism.

[0033] In a preferred embodiment, the horizontal transmission mechanism employs a horizontally arranged first hydraulic press 31. The cylinder body of the first hydraulic press 31 is fixed to one end of the support platform 21 by a support, and its piston end extends and retracts laterally. The vertical lifting mechanism employs a vertically arranged second hydraulic press 41, whose hydraulic cylinder is connected to the piston end of the first hydraulic press 31, and the end of the piston end of the second hydraulic press 41 is connected to the lifting device 5.

[0034] The intelligent operation of the entire tooling is controlled by controller 8, which is installed on the base. Controller 8 is connected to the control input terminals of servo motor 25, horizontal transmission machine and vertical lifting machine via cables.

[0035] Furthermore, to achieve closed-loop control, displacement sensors are installed at least two locations on the platform, at the transmission output end of the horizontal drive mechanism, and at the transmission output end of the vertical lift mechanism. Since the conventional guardrail installation process typically involves adjusting the longitudinal and lateral guardrail postures first, and then adjusting the height, this invention installs a first displacement sensor on the platform and a second displacement sensor at the transmission output end of the horizontal drive mechanism. The first and second displacement sensors are used to capture the longitudinal displacement data of the platform 21 and the lateral movement data of the horizontal drive mechanism in real time, respectively, and convert these physical quantities into digital signals, which are then fed back to the controller 8 via a bus. The first and second displacement sensors can be, for example, high-precision optical encoders, with a sensing accuracy down to 0.01 mm, achieving high-precision control.

[0036] The controller 8 also integrates a precision compensation control module, which calculates the vector deviation of the adjustment mechanism in each dimension in real time based on the actual process data fed back by the displacement sensor, and sends attitude adjustment control pulses to the horizontal transmission machine, the vertical lifting machine and the servo motor 25.

[0037] Specifically, in actual operation, due to a combination of factors such as mechanical transmission, materials, and stress, the platform 21 may experience slight elastic deformation or tilting, causing a shift in the previously adjusted longitudinal or lateral coordinates. The precision compensation control module receives real-time progress data from various sensors and calculates the displacement deviation in the current dimension using a preset vector calculation formula. For example, when the operator instructs for height fine-tuning, the controller 8 simultaneously locks the current longitudinal and lateral positions as a reference. If the displacement sensor in the longitudinal dimension detects displacement data during the lifting process, the controller 8 immediately sends a compensation pulse to the servo motor 25. The servo motor 25 generates a small reverse displacement based on this pulse, thereby offsetting the error caused by mechanical linkage. This multi-dimensional decoupling control technology ensures that the adjustments in the three axes do not interfere with each other, resulting in an extremely high first-time alignment success rate.

[0038] To further improve control efficiency and precision, dual-speed frequency converters are integrated into the power ends of the servo motor 25, the horizontal transmission, and the vertical lifting platform. This component, controlled by the logic instructions of the controller 8, can switch between coarse and fine adjustment modes. In the initial stages of construction, when the prefabricated guardrail 7 is far from the installation point, the dual-speed frequency converter outputs high-frequency current, driving each actuator at a first speed (2-10 mm / s in this example) to improve the attitude adjustment efficiency of each adjustment mechanism. When the guardrail approaches the installation position, the system switches to fine adjustment mode, and the frequency converter outputs low-frequency current, driving the actuator at a second speed (0.5-1 mm / s in this example). This allows the mechanical system to make fine adjustments in millimeter-level increments, effectively avoiding the need for corrections due to incomplete adjustments caused by high-speed inertia in the coarse adjustment mode.

[0039] In practical applications, the usage of this invention is as follows: Step S1: First, the equipment is installed and physically fixed. The forklift driver adjusts the width of the forklift forks 6 to correspond to the width of the tooling slot. Then, the driver inserts the forklift forks 6 into the slot 11 of the base 1. The tooling and forks 6 are rigidly locked by setting a pin 15 on the slot, ensuring that the lifting power of the forklift can be transmitted to the base 1 without loss, eliminating the swaying gap during the subsequent lifting process.

[0040] Step S2, then proceeds to the component transfer stage. A sling is installed on the prefabricated guardrail 7. After connecting the lifting device 5 to the sling, the forklift lifts the prefabricated guardrail 7 and transfers the guardrail to the working surface at the guardrail installation position determined by the surveyor. A distance sensor is installed at the bottom of the guardrail facing the bridge surface corresponding to the predetermined installation position of the guardrail. In this example, an ultrasonic distance sensor is used to transmit ultrasonic waves to the ground and feed back the distance between the guardrail and the ground to the controller 8 in real time.

[0041] In step S3, the operator then uses the forklift's hydraulic system to make a wide-range height adjustment, lowering the forks 6 so that the guardrail is roughly close to the installation elevation. Afterward, the forklift and forks 6 are locked. Next, the controller 8 drives the dual-speed frequency converter into coarse adjustment mode. The servo motor 25, horizontal transmission, and vertical lifting mechanism work together to quickly bring the guardrail close to the installation position. During this period, surveyors further determine the positioning indicators of the guardrail installation location and report the installation posture to the tooling operator via walkie-talkie or other real-time communication methods.

[0042] In step S4, when the height value fed back by the distance sensor enters the fine-tuning threshold range (set to 50 mm from the pre-embedded steel bar on the bridge deck in this example), the system automatically switches to fine-tuning mode. The operator then fine-tunes the attitude of the guardrail in each of the horizontal and vertical dimensions according to the surveying and positioning indicators, until the guardrail reaches the corresponding surveying and positioning position in that dimension before fine-tuning the height dimension. During height fine-tuning, the controller 8 executes the accuracy compensation control process for other dimensions, driving the adjustment mechanisms in other dimensions to perform reverse compensation for displacement changes in other dimensions caused during height fine-tuning. For example, before height adjustment, the controller 8 records the data from the adjusted horizontal and vertical displacement sensors. During height fine-tuning, if the data from the vertical displacement sensor changes, the controller 8 immediately calculates the vector difference between the current data and the recorded data in real time, and sends the vector difference as a strain compensation amount to the servo motor 25 to send an attitude adjustment control pulse, driving the servo motor 25 to adjust in the reverse direction to compensate for the displacement deviation until the displacement sensor data in that dimension is reset to the original recorded data.

[0043] Furthermore, it should be noted that in the above implementation process, since the horizontal adjustment mechanism 3 of this embodiment is provided with two guide grooves 32, and the corresponding height adjustment mechanism 4 is also provided with two, when the assembled guardrail is operated by a forklift, if the forklift is not in the correct position, the horizontal transmission mechanism in each guide groove 32 can be controlled to extend and retract at different stages to realize the horizontal angle rotation of the guardrail so that it is level with the predetermined installation position; and the vertical lifting mechanism can be controlled to extend and retract at different stages to realize the tilt angle adjustment of the guardrail so that it is parallel to the installation surface.

[0044] Specifically, taking the installation of prefabricated guardrails at a bridge construction site as a specific implementation scenario, the prefabricated guardrails are adjusted in the order of longitudinal, lateral, and height, and this is done using a hydraulic method. After the guardrail installation posture is roughly adjusted to the predetermined installation position, the guardrail still needs to be finely adjusted in various dimensions, which corresponds to the process in step S4 above as follows: Longitudinal: Based on the surveyed positioning indicators, the servo motor 25 is started, and the generated rotational torque is transmitted to the screw 23. Since the screw 23 and the nut seat 24 fixed at the bottom of the base 1 form a helical transmission, the rotation of the screw 23 is converted into a linear thrust of the support platform 21 along the guide rail 13. At this time, the bearing wheel group 22 at the bottom of the support platform 21 rolls on the guide rail 13, driving all the adjustment mechanisms above to move longitudinally along the sliding groove 12. This helical transmission principle can linearly amplify the rotational accuracy of the motor to the millimeter-level linear positioning accuracy, and by utilizing the self-locking characteristic of the helix angle, the static locking of the support platform 21 can be achieved the instant the motor stops, ensuring the stability of the prefabricated guardrail 7 in the longitudinal coordinate. During this process, the first displacement sensor on the support platform transmits the displacement data of the support platform to the controller 8 in real time. When the longitudinal adjustment is completed so that the position of the prefabricated guardrail 7 matches the longitudinal dimension position corresponding to the surveyed indicators, the servo motor 25 is turned off, and the data of the first displacement sensor at this time is recorded.

[0045] Laterally: The controller 8 supplies hydraulic oil to the hydraulic cylinder of the first hydraulic press 31, driving the piston end to extend and retract laterally along the guide groove 32. When the piston rod of the first hydraulic press 31 extends, it drives the vertical lift and the lifting device 5 connected to it to move laterally synchronously. At the same time, the positioning wheel 33 on the outer periphery of the piston rod end rolls in the positioning groove 34 on the side wall of the guide groove 32, providing guidance and support for the lateral movement, effectively preventing deflection that may be caused by the cantilever effect, and ensuring the straightness and stability of the lateral adjustment. Meanwhile, the second displacement sensor on the piston rod of the first hydraulic press 31 transmits the displacement data of the lateral adjustment mechanism 3 to the controller 8 in real time until the guardrail reaches the lateral dimension position corresponding to the surveying index, maintains the current state of the cylinder of the first hydraulic press 31, and records the displacement data of the second displacement sensor at this time.

[0046] Height: Controller 8 supplies hydraulic oil to the hydraulic cylinder of the second hydraulic press 41, driving its piston end to vertically raise and lower the lifting device 5 and the assembled guardrail 7. During height adjustment, the first and second displacement sensors monitor the displacement changes of the longitudinal adjustment mechanism 2 and the lateral adjustment mechanism in real time. If a slight displacement occurs in the lateral or longitudinal dimension due to mechanical linkage or external factors, the precision compensation control module in controller 8 will immediately activate. Based on the deviation data fed back by the corresponding dimension displacement sensor, it drives the lateral or longitudinal adjustment mechanism 2 to perform reverse compensation to maintain the adjusted lateral and longitudinal position accuracy, thereby ensuring the independence and accuracy of height adjustment.

[0047] Through the independent and coordinated precise control of the three dimensions of horizontal, vertical and height, combined with the mode switching of the dual-speed frequency converter and the real-time correction of the precision compensation control module, the present invention can efficiently and accurately complete the installation and alignment of the prefabricated guardrail 7, significantly improving the quality and efficiency of the installation of the prefabricated guardrail 7 in bridge construction.

[0048] Furthermore, to enhance the safety of the tooling used in this invention, a pressure sensor is installed at the connection point of the lifting device 5. This pressure sensor monitors the load distribution of the guardrail. If the pressure difference between two lifting points exceeds a preset balance threshold (e.g., the pressure at one lifting point is more than 20% greater than the pressure at the other), it indicates that the guardrail may have experienced unilateral jamming or a severe shift in its center of gravity during descent. In this case, the controller 8 instantly cuts off the power to all actuators and activates the mechanical self-locking device to prevent the guardrail from tipping over. Afterwards, manual intervention is performed to inspect each component, adjust the guardrail's lifting status, and confirm that the load difference has returned to a safe threshold before restarting the machine to continue the installation work. Under the real-time monitoring of the pressure sensor, the vertical lift slowly descends until the guardrail is smoothly positioned on the pre-embedded reinforcing steel bars on the bridge deck.

[0049] This invention constructs a complete end-effector system for the installation of prefabricated guardrails 7 by organically combining a base 1, a longitudinal adjustment mechanism 2, a lateral adjustment mechanism 3, a height adjustment mechanism 4, and an intelligent controller 8. It successfully combines the mobility of a forklift with the fine-tuning capabilities of precision machinery, solving the positioning problem in the installation of prefabricated components. Furthermore, the multi-sensor fusion precision compensation technology fundamentally solves the interference problem of multi-dimensional adjustments. The widespread application of this device will significantly improve the industrialization level of prefabricated guardrail installation 7, reduce labor intensity, shorten the construction cycle, and provide a solid technical guarantee for the aesthetic alignment of bridge projects.

[0050] In another embodiment of the invention, to meet more precise adjustment requirements, the horizontal transmission mechanism can employ a worm gear drive pair. The worm gear drive pair includes a first worm gear seat fixed to the edge of the pier 21, a transverse transmission screw screwed into the worm gear seat, and a first motor providing power to the transmission screw. Correspondingly, the vertical lifting mechanism can also employ a worm gear lifting pair, which includes a second worm gear seat vertically connected to the end of the screw of the worm gear drive pair, a lifting screw screwed into the second worm gear seat, and a second motor providing rotational power to the lifting screw. The end of the lifting screw is connected to the lifting device 5. This mechanical transmission method has better rigidity and smaller backlash error compared to hydraulic transmission, which can not only further improve positioning accuracy and meet the stringent requirements of large bridges for guardrail alignment, but also utilize the self-locking characteristic of the screw drive to perform static displacement locking when the motor stops, ensuring that the guardrail will not shift due to gravity or wind load after positioning in all dimensions. The displacement sensor, controller 8, and related control logic in the above scheme can all act equivalently on the worm gear drive pair and the worm gear lifting pair.

[0051] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A prefabricated guardrail three-dimensional alignment and fine-tuning and rapid installation fixture, characterized in that, include: The base has a slot on the side for forklift forks to enter, and a sliding groove in the middle, with a guide rail installed on the side wall of the sliding groove. The longitudinal adjustment mechanism includes a support platform mounted on the guide rail and capable of reciprocating along the guide rail, a servo motor that drives the displacement of the support platform, and a first displacement sensor that monitors the longitudinal displacement of the support platform. The lateral adjustment mechanism is located above the pier and includes at least two guide grooves fixed on the pier, a horizontal transmission machine arranged in the guide grooves along the transverse direction of the bridge, and a second displacement sensor for monitoring the transmission displacement of the horizontal transmission machine. The height adjustment mechanism is vertically connected to the transmission output end of the horizontal transmission machine, and includes a vertical lifting machine that can control vertical lifting and a lifting device installed at the bottom of the vertical lifting machine; The controller is electrically connected to the servo motor, the horizontal transmission machine, the vertical lifting machine, the first displacement sensor, and the second displacement sensor, respectively. The controller integrates a precision compensation control module, which is used to perform real-time reverse compensation for displacement deviations in non-adjustment dimensions based on feedback data from the displacement sensors.

2. The prefabricated guardrail three-dimensional alignment and fine-tuning and rapid installation fixture according to claim 1, characterized in that, The base has several through pin holes at the corresponding positions of the insertion slots. Pins are installed in the pin holes to lock and fix the forks after they are inserted into the insertion slots.

3. The prefabricated guardrail three-dimensional alignment and fine-tuning and rapid installation fixture according to claim 2, characterized in that, The longitudinal adjustment mechanism also includes a bearing wheel assembly, a screw, and a nut seat; the bearing wheel assembly is installed at the bottom of the platform and rolls in cooperation with the guide rail; the output shaft of the servo motor is connected to the screw, the nut seat is fixed at the bottom of the sliding groove, the screw is screwed to the nut seat, and the servo motor drives the screw to rotate, thereby driving the platform to generate longitudinal displacement.

4. The prefabricated guardrail three-dimensional alignment and fine-tuning and rapid installation fixture according to claim 3, characterized in that, A positioning wheel is provided on the outer periphery of the output end of the horizontal transmission machine, and a positioning groove matching the positioning wheel is opened on the inner surface of the side wall of the guide groove. The positioning wheel rolls in the positioning groove to provide horizontal support for the transmission output end of the horizontal transmission machine.

5. The prefabricated guardrail three-dimensional alignment and fine-tuning and rapid installation fixture according to claim 4, characterized in that, The power input terminals of the servo motor, horizontal transmission, and vertical lifting platform are all connected to a dual-speed frequency converter. The dual-speed frequency converter is controlled by the controller and is used to switch between a coarse adjustment mode in which the servo motor, horizontal transmission, and vertical lifting platform operate at a first speed or a fine adjustment mode in which they operate at a second speed, and the first speed is greater than the second speed.

6. The prefabricated guardrail three-dimensional alignment and fine-tuning and rapid installation fixture according to claim 5, characterized in that, The horizontal transmission machine is a first hydraulic press, and the vertical lifting machine is a second hydraulic press. The hydraulic cylinder of the second hydraulic press is vertically connected to the piston end of the first hydraulic press, and the piston end of the second hydraulic press is connected to the lifting device.

7. The prefabricated guardrail three-dimensional alignment and fine-tuning and rapid installation fixture according to claim 5, characterized in that, The horizontal transmission mechanism includes a first worm gear seat fixed on the support platform, a transverse transmission screw screw screwed into the first worm gear seat, and a first motor driving the transverse transmission screw screw; the vertical lifting mechanism includes a second worm gear seat connected to the end of the transverse transmission screw screw, a lifting screw screw screwed into the second worm gear seat, and a second motor driving the lifting screw screw.

8. The method of using the prefabricated guardrail three-dimensional alignment and fine-tuning and rapid installation fixture according to claim 6 or 7, characterized in that, Includes the following steps: Step S1, Equipment fixing: Insert the forklift forks into the insertion slot of the tooling, and lock the base and forks together with the pins; Step S2, component transfer: The prefabricated guardrail is lifted to the installation position using a lifting device, and a distance sensor facing the bridge surface is installed at the bottom of the guardrail; Step S3, coarse adjustment positioning: The controller drives the dual-speed frequency converter to enter the coarse adjustment mode, and coordinates the various adjustment mechanisms to make the guardrail quickly approach the installation posture. Step S4, fine-tuning compensation: When the data fed back by the distance sensor reaches the preset value, the controller drives the dual-speed frequency converter to switch to fine-tuning mode, and performs fine-tuning in the longitudinal and lateral dimensions in sequence. After the guardrail reaches the preset installation position in the corresponding dimension, the displacement data of the first displacement sensor and the second displacement sensor are recorded at this time. Then, fine-tuning in the height dimension is performed. During this period, the precision compensation control module obtains the deviation data of the first and second displacement sensors in real time and drives the servo motor or horizontal transmission to perform reverse displacement compensation until the displacement data is reset.

9. The method for using the prefabricated guardrail three-dimensional alignment and fine-tuning and rapid installation fixture according to claim 8, characterized in that, During the height fine-tuning in step S4, if the first displacement sensor or the second displacement sensor detects a change in displacement data, the controller calculates the vector difference between the current displacement data and the recorded displacement data in real time, and sends a control pulse to the power end of the servo motor or horizontal transmission as a compensation amount to drive it to adjust in the opposite direction to offset the error generated by the mechanical linkage.

10. The method for using the prefabricated guardrail three-dimensional alignment and fine-tuning and rapid installation fixture according to claim 9, characterized in that, Step S1 also includes installing pressure sensors on the lifting devices to acquire load data of each lifting device carrying the guardrail in real time during the guardrail installation construction; Steps S3 and S4 include monitoring the load of the lifting devices. When the load data of each lifting device is unbalanced and the difference exceeds the preset safety threshold, the controller immediately stops and locks all adjustment mechanisms; then, manual intervention is used to check each component, adjust the guardrail lifting status, and after confirming that the load difference has returned to the safety threshold, the machine is restarted to continue the installation work.

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