Ship lock head seamless one-time casting molding process and system

Abstract

This application relates to the field of hydraulic engineering construction technology, and provides a seamless one-time casting process and system for lock head. The seamless one-time casting process for lock head includes the following steps: a) Construction preparation and condition assessment; b) Elimination of wide joints: The longitudinal construction wide joints reserved between the upper lock head side pier and the middle bottom plate are eliminated, and the original segmented casting of the middle bottom plate and the wide joint area are integrated into a single casting unit; c) Adjustment of concrete mix ratio: The water-cement ratio in the concrete is set to 0.4, fly ash and mineral powder are added to the concrete, and the amount of water-reducing agent is reduced; d) Pre-embedded cooling water pipes; e) One-time concrete casting: The concrete is cast in layers from bottom to top; f) Active temperature control measures: After the concrete is cast, circulating water is introduced into the cooling water pipes; g) Demolding and curing; h) Acceptance. This seamless one-time casting process for lock head significantly shortens the construction cycle of the upper lock head.

Description

Technical Field

[0001] This application relates to the field of water conservancy engineering construction technology, and more specifically, to a one-time casting molding process and system for the gate head of a ship lock without wide gaps. Background Technology

[0002] In the design of large-volume concrete structures for the gate heads of medium and large ship locks, traditional methods commonly incorporate longitudinal construction joints with varying widths. This design is primarily based on three considerations: first, by pouring concrete in sections and layers, it releases the heat of hydration generated during hardening, controls the internal and external temperature differences, and prevents the formation of temperature cracks; second, it accommodates soil settlement and structural deformation behind the wall during construction, reduces the foundation's restraint effect, and avoids harmful through-cracks caused by uneven settlement; and third, it actively adjusts the distribution of internal forces within the structure, improving overall load-bearing capacity. However, on-site construction revealed significant drawbacks:

[0003] 1. Long construction time leads to low efficiency; 2. Quality risk: Wide joints, as the interface between new and old concrete, are prone to leakage if not thoroughly roughened or compacted; 3. Structural performance defects: Wide joints disrupt the continuity of concrete, and even if backfilled later, the overall stiffness is reduced by 10% to 15% compared to a one-time cast structure, making it prone to stress concentration under long-term water and soil pressure. Summary of the Invention

[0004] In view of this, this application provides a one-time casting process for lock head without wide joints, in order to solve the technical problem of low construction efficiency of the existing lock head casting process based on wide joint construction.

[0005] This application provides a seamless, one-time casting process for lock head, wherein the seamless, one-time casting process for lock head includes the following steps: a. Construction preparation and condition assessment: Based on the on-site measured data, it was determined that the backfilling behind the wall had been completed and the settlement of the side piers had stabilized; b. Cancel the wide joint: Cancel the longitudinal construction wide joint reserved between the upper gate head pier and the middle bottom plate, integrate the original segmented middle bottom plate and the wide joint area into a whole casting unit, and cancel the original closing mesh on the inside of the wide joint and the connecting structural steel bars on both sides. c. Adjust the concrete mix proportion: Set the water-cement ratio in the concrete to 0.4, add fly ash and mineral powder to the concrete, and reduce the amount of water-reducing agent. d. Pre-embedded cooling water pipes: Cooling water pipes are installed inside the base plate; e. One-time concrete pouring: pour concrete in layers from bottom to top, with each layer less than or equal to 30cm thick and each layer taking less than or equal to 2 hours to pour; pour concrete symmetrically from both sides of the gate head towards the middle, using a vibrator for compaction, with a compaction interval of ≤30cm and a compaction time of 20 to 30 seconds. f. Active temperature control measures: After the concrete is poured, circulating water is introduced into the cooling water pipes; g. Demolding and curing: After the demolding strength is reached, remove the formwork, cover it with a moisturizing and curing layer, and cure it by sprinkling or running water for no less than 14 days. h. Acceptance: Conduct tests on appearance, strength, density, and leakage. Once the tests are passed, proceed with subsequent construction.

[0006] Furthermore, in step a, a high-precision hydrostatic level and a GNSS displacement monitoring station are used to monitor the settlement of the pier. Data is automatically collected at a frequency of no less than once per hour and uploaded to the cloud central control platform in real time. The cloud central control platform automatically calculates the diurnal average settlement rate over 30 days. When the diurnal average settlement rate is less than 0.1 mm and this condition is met for no less than 3 consecutive days, the cloud central control platform generates a "stabilized pier settlement" judgment information and pushes the "stabilized pier settlement" judgment information to the management terminal equipment.

[0007] Furthermore, the concrete mix proportion in step c is generated by the following method: establishing a raw material performance database, collecting on-site environmental parameters, taking a water-cement ratio of 0.4 as the target, and using fly ash content, mineral powder content, water-reducing agent content, and sand ratio as optimization variables, with slump, initial setting time, strength, and heat of hydration as constraints, and automatically generating the optimal construction mix proportion through genetic algorithm or Bayesian optimization and sending it to the mixing plant.

[0008] Furthermore, in step f, the cooling water flow rate and water temperature are automatically adjusted based on the real-time feedback data from the pre-embedded temperature sensor. When the internal and external temperature difference is <20℃, the current flow rate and water temperature are maintained; when the internal and external temperature difference is 20℃~23℃, the flow rate is increased by 0.2m³ / h; when the internal and external temperature difference is 23℃~24.5℃, the flow rate is increased to 1.5m³ / h and the water temperature is reduced by 2℃; when the internal and external temperature difference is ≥24.5℃, the flow rate is adjusted to the maximum value of 2.0m³ / h, the water temperature is reduced to the minimum allowable value (not lower than 5℃), and an orange warning is issued; when the internal and external temperature difference is ≥25℃, a red alarm is issued and the circulation is forcibly increased; after the internal and external temperature difference falls back to below 20℃, the flow rate is gradually reduced and the water temperature is increased, controlling the cooling rate to ≤2℃ / d.

[0009] Furthermore, the moisturizing and protective layer described in step g is equipped with multiple distributed optical fiber humidity sensors arranged in sequence, with a spacing of 1m to 3m between adjacent distributed optical fiber humidity sensors, in order to monitor the humidity in the moisturizing and protective layer in real time. When any distributed optical fiber humidity sensor detects that the humidity is lower than 92%RH, the humidity in the moisturizing and protective layer is restored to above 95%RH by spraying.

[0010] Furthermore, step e also includes: using a small vibrator to vibrate the concrete at the edge of the formwork between the formwork and the reinforcing bars to remove air bubbles at the edge of the formwork.

[0011] Furthermore, the present invention also provides a seamless one-time casting molding system for lock head, wherein the seamless one-time casting molding system for lock head is used to implement the above-mentioned seamless one-time casting molding process for lock head, and the seamless one-time casting molding system for lock head includes: The concrete supply system includes a batching plant, concrete mixer trucks, and pumping equipment. Template system; Cooling water piping system, including cooling water pipes embedded in the base plate; Temperature monitoring system, including a temperature sensor installed in the cooling water pipe; Vibration device, including vibrator and small vibrating rod; The system includes a main controller, a high-precision hydrostatic level, a GNSS displacement monitoring station, and a cloud-based central control platform. The main controller is connected to the high-precision hydrostatic level, the GNSS displacement monitoring station, the cloud-based central control platform, the cooling water pipeline system, and the temperature monitoring system.

[0012] Further, the small vibratory rod includes a shell, a vibration drive motor, a rotation drive motor, a vibratory rod body, and a vibratory sleeve disposed on the outside of the vibratory rod body. The vibration drive motor is mounted on the shell to drive the shell to vibrate. The rotation drive motor is mounted on the shell, and the output shaft of the rotation drive motor extends into the shell and is equipped with a first gear. The vibratory rod body is rotatably mounted on the shell. The upper end of the vibratory rod body extends into the shell and is equipped with a second gear. The first gear meshes with the second gear. The vibratory sleeve is provided with multiple gas passage holes. A gap space is formed between the vibratory sleeve and the outside of the vibratory rod body. A central air channel extending along its axis is formed inside the vibratory rod body. The central air channel extends through the upper end of the vibratory rod to form an exhaust hole. A guide air channel is formed inside the vibratory rod body. One end of the guide air channel is connected to the central air channel, and the other end of the guide air channel extends through the outside of the vibratory rod body and connects to the gap space.

[0013] Furthermore, the housing is provided with an air guide tube, the first end of the air guide tube and the exhaust hole are able to be sealed and fitted relative to each other about the axis of the vibrating rod body, and the second end of the air guide tube extends out of the housing.

[0014] Furthermore, an air pump is connected to the second end of the air duct.

[0015] The beneficial effects of the seamless, one-time casting molding process for lock heads provided by this invention are as follows: Compared to existing technologies, the one-time casting process for the lock head without wide joints provided in this application eliminates the longitudinal construction joints reserved between the upper lock head side pier and the middle bottom plate. It integrates the originally segmented casting of the middle bottom plate and the wide joint area into a single casting unit, and eliminates the original sealing mesh on the inner side of the wide joint and the connecting structural steel bars on both sides. Furthermore, the one-time concrete casting significantly shortens the construction cycle of the upper lock head, improves construction efficiency, and creates favorable conditions for metal structure installation. In terms of later maintenance, one-time casting eliminates the risk of leakage at the interface between new and old concrete, avoiding maintenance or repair costs caused by leakage later, resulting in significant overall economic benefits. In addition, the workload of tying reinforcing bars is reduced, and the formwork engineering is simplified (eliminating the need for separate formwork erection, demolding, and secondary formwork erection for the wide joint), directly shortening the construction period. One-time casting improves structural continuity and waterproofing, eliminates the interface between new and old concrete, and, combined with optimized vibration and curing, ensures a leak-free structure. It eliminates the need for secondary formwork erection, roughening, and backfilling, reducing concrete waste and achieving green construction. By optimizing the concrete mix ratio, improving temperature control measures, and standardizing the pouring process, the problems of hydration heat and density in one-time pouring are solved. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a simplified schematic diagram of the process for one-time casting and molding of a lock head without wide gaps, according to an embodiment of this application. Figure 2 This is a schematic diagram illustrating the principle of a seamless, one-time casting system for lock head according to an embodiment of this application. Figure 3 This is a three-dimensional schematic diagram of a small vibratory rod in a one-time casting molding system for a lock head without wide gaps, according to an embodiment of this application. Figure 4 for Figure 3 Enlarged view of point A in the middle; Figure 5 This is a three-dimensional schematic diagram of a small vibratory rod in a one-time casting molding system for a lock head without a wide gap, according to an embodiment of this application. Figure 6 This is a partial assembly diagram of a small vibratory rod in a seamless, one-time casting system for lock head according to an embodiment of this application.

[0018] Explanation of reference numerals in the attached figures: 1-Shell; 2-Vibration drive motor; 3-Rotation drive motor; 4-First gear; 5-Second gear; 6-Air guide tube; 7-Operator handle; 15-Interval space; 100-Vibrator rod body; 101-Central air channel; 102-Air guide channel; 200-Vibration sleeve; 201-Gas passage hole. Detailed Implementation

[0019] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings. One or more embodiments of this application are exemplarily shown in the drawings to provide a more accurate and thorough understanding of the technical solutions disclosed herein. However, it should be understood that this application can be implemented in many different forms and is not limited to the embodiments described below.

[0020] In the accompanying drawings of this application, the same or similar reference numerals correspond to the same or similar components. In the description of this application, it should be understood that if terms such as "upper," "lower," "left," "right," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they 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. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting this application. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0021] Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, if "and / or" or "and / or" appears throughout the text, its meaning includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously.

[0022] Furthermore, the technical solutions of the various embodiments can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0023] See Figure 1 This application provides a seamless one-time casting molding process for lock head, which includes the following steps: a. Construction preparation and condition assessment: Based on the on-site measured data, it was determined that the backfilling behind the wall had been completed and the settlement of the side piers had stabilized; In addition, after step a, the excavation of reserved soil and foundation treatment can be carried out: excavate to the design bottom elevation, measure the foundation elevation and edge outline, and pour the replacement concrete cushion layer. b. Cancel the wide joint: Cancel the longitudinal construction wide joint reserved between the upper gate head pier and the middle bottom plate, integrate the original segmented middle bottom plate and the wide joint area into a whole casting unit, and cancel the original closing mesh on the inside of the wide joint and the connecting structural steel bars on both sides. c. Adjust the concrete mix proportion: Set the water-cement ratio in the concrete to 0.4, add fly ash and mineral powder to the concrete, and reduce the amount of water-reducing agent. d. Pre-embedded cooling water pipes: Cooling water pipes are installed inside the base plate; e. One-time concrete pouring: Pour concrete in layers from bottom to top, with each layer less than or equal to 30cm thick and each layer taking less than or equal to 2 hours to avoid cold joints between layers; pour symmetrically from both sides of the gate head towards the center to avoid uneven pressure caused by pouring on one side; use a vibrator for compaction, with a compaction interval ≤30cm and a compaction time of 20 to 30 seconds (until no air bubbles overflow and slurry appears on the concrete surface), to avoid under-vibration or over-vibration. f. Active temperature control measures: After the concrete is poured, circulating water is introduced into the cooling water pipe. Specifically, the cooling water pipe is a Φ50mm galvanized steel pipe arranged in the base plate at a spacing of "1m×1m". After the concrete is poured, 20℃ circulating water is introduced. The temperature difference between the inside and outside is controlled to be <25℃ by real-time monitoring through temperature sensors installed in the cooling water pipe. g. Demolding and curing: After the demolding strength is reached, remove the formwork, cover it with a moisturizing and curing layer, and cure it by sprinkling or running water for no less than 14 days. h. Acceptance: Conduct tests on appearance, strength, density, and leakage. Once the tests are passed, proceed with subsequent construction.

[0024] Because the lock head one-time casting process without wide joints provided in this application eliminates the longitudinal construction wide joints reserved between the upper lock head side pier and the middle bottom plate, the originally segmented middle bottom plate and the wide joint area are integrated into a single casting unit. The original inner sealing mesh and connecting structural steel bars on both sides of the wide joint are also eliminated, and concrete is poured in one go. Eliminating the wide joint significantly shortens the construction cycle of the upper lock head, improves construction efficiency, and creates favorable conditions for metal structure installation. In terms of later maintenance, one-time casting eliminates the risk of leakage at the interface between new and old concrete, avoiding maintenance or repair costs caused by leakage later, resulting in significant overall economic benefits. Furthermore, the workload of tying reinforcing bars is reduced, and the formwork engineering is simplified (no longer requiring separate formwork erection, demolition, and secondary formwork erection for the wide joint), directly shortening the construction period. One-time casting improves structural continuity and waterproofing, eliminates the interface between new and old concrete, and, combined with optimized vibration and curing, ensures a leak-free structure. It eliminates the need for secondary formwork erection, roughening, and backfilling, reducing concrete waste and achieving green construction. By optimizing the concrete mix ratio, improving temperature control measures, and standardizing the pouring process, the problems of hydration heat and density in one-time pouring are solved.

[0025] In addition, the "stepped" method of layered pouring from bottom to top is adopted, with each layer thickness controlled within 30cm. Specifically, the pouring time for each layer is ≤2h to avoid cold joints between layers. The pouring sequence is symmetrical from both sides of the gate head towards the middle to avoid unilateral pressure caused by pouring on one side. Vibration control is well done, with vibration spacing ≤30cm and vibration time of 20 to 30 seconds (until no air bubbles overflow and slurry rises to the surface of the concrete) to avoid under-vibration or over-vibration.

[0026] According to a specific embodiment of this application, the water-cement ratio is adjusted from 0.38 to 0.40. While meeting the C30 strength requirement, the cement dosage is reduced (from 337 kg / m³ to 163 kg / m³), thus reducing the heat of hydration. The original expansion agent (34 kg / m³) is replaced with a dual admixture of fly ash and mineral powder (totaling 163 kg / m³), which reduces costs (the unit price of the dual admixture is 40% lower than that of the expansion agent) and improves concrete density through a secondary hydration reaction, reducing shrinkage cracks. The water-reducing agent dosage is reduced from 4.21 kg / m³ to 3.25 kg / m³, adapting to the low cement dosage system and ensuring a stable slump of 140 ± 20 mm, meeting the requirements for pumping and pouring.

[0027] According to one embodiment of this application, in step a, a high-precision hydrostatic level and a GNSS displacement monitoring station are used to monitor the settlement of the pier. Data is automatically collected at a frequency of not less than once per hour and uploaded to the cloud central control platform in real time. The cloud central control platform automatically calculates the diurnal average of the settlement rate over 30 days. When the diurnal average is <0.1mm and this condition is met continuously for not less than 3 days, the cloud central control platform generates a judgment information that "the settlement of the pier has stabilized" and pushes the judgment information that "the settlement of the pier has stabilized" to the management terminal device.

[0028] According to one embodiment of this application, the concrete mix proportion in step c is generated by the following method: establishing a raw material performance database, collecting on-site environmental parameters, taking a water-cement ratio of 0.4 as the target, and using fly ash content, mineral powder content, water-reducing agent content, and sand ratio as optimization variables, and using slump, initial setting time, strength, and heat of hydration as constraints, the optimal construction mix proportion is automatically generated through a genetic algorithm or Bayesian optimization and sent to the mixing plant.

[0029] According to one embodiment of this application, step e involves configuring multiple vibrators and dividing the pouring area into multiple vibration zones via a cloud-based central control platform. The vibration operation times of adjacent vibration zones are staggered by 10 to 15 seconds to avoid mutual interference of excitation waves. The operation progress of each vibrator is tracked in real time, and when the vibration coverage rate is detected to be less than 90%, it is automatically marked as an area requiring additional vibration and guided to undergo additional vibration.

[0030] According to one embodiment of this application, in step f, the cooling water flow rate and water temperature are automatically adjusted based on the real-time feedback data from the pre-embedded temperature sensor. When the internal and external temperature difference is <20℃, the current flow rate and water temperature are maintained; when the internal and external temperature difference is 20℃~23℃, the flow rate is increased by 0.2m³ / h; when the internal and external temperature difference is 23℃~24.5℃, the flow rate is increased to 1.5m³ / h and the water temperature is reduced by 2℃; when the internal and external temperature difference is ≥24.5℃, the flow rate is adjusted to the maximum value of 2.0m³ / h, the water temperature is reduced to the minimum allowable value (not lower than 5℃), and an orange warning is issued; when the internal and external temperature difference is ≥25℃, a red alarm is issued and the circulation is forcibly increased; after the internal and external temperature difference falls back to below 20℃, the flow rate is gradually reduced and the water temperature is increased, controlling the cooling rate to ≤2℃ / d.

[0031] According to one embodiment of this application, in step g, the moisturizing and protective layer is equipped with a plurality of distributed optical fiber humidity sensors arranged in sequence, with a spacing of 1m to 3m between adjacent distributed optical fiber humidity sensors, so as to monitor the humidity in the moisturizing and protective layer in real time. When any distributed optical fiber humidity sensor detects that the humidity is lower than 92%RH, the humidity in the moisturizing and protective layer is restored to above 95%RH by spraying.

[0032] According to one embodiment of this application, step e further includes: using a small vibrator to vibrate the concrete at the edge of the formwork between the formwork and the reinforcing bars to remove air bubbles at the edge of the formwork.

[0033] See Figures 2 to 6 This application also provides a seamless one-time casting molding system for lock head, wherein the seamless one-time casting molding system for lock head is used to implement the above-mentioned seamless one-time casting molding process for lock head, and the seamless one-time casting molding system for lock head includes: The concrete supply system includes a batching plant, concrete mixer trucks, and pumping equipment. The formwork system may specifically include large combined steel formwork or high-strength plywood formwork, formwork support frame, tie rods and fasteners, used to enclose the pouring space of the integrated base slab; Cooling water piping system, including cooling water pipes embedded in the base plate; Temperature monitoring system, including temperature sensors installed in cooling water pipes; Vibration device, including vibrator and small vibrating rod; The system includes a main controller (e.g., an industrial computer), a high-precision hydrostatic level, a GNSS displacement monitoring station (also known as a GNSS monitoring station or GNSS displacement monitor, which is a device used for monitoring surface displacement and building deformation, mainly including GNSS antenna, solar panels, main control chassis and mounting brackets, etc.), and a cloud-based central control platform. The main controller is connected to the high-precision hydrostatic level, concrete supply system, GNSS displacement monitoring station, cloud-based central control platform, cooling water pipe network system, and temperature monitoring system.

[0034] According to one embodiment of this application, a small vibratory tamping rod includes a housing 1, a vibration drive motor 2, a rotation drive motor 3, a vibratory tamping rod body 100, and a vibratory sleeve 200 disposed on the outside of the vibratory tamping rod body 100. The vibratory sleeve 200 can be integrally formed with the vibratory tamping rod body 100. The vibration drive motor 2 is mounted on the housing 1 to drive the housing 1 to vibrate. The rotation drive motor 3 is mounted on the housing 1, and the output shaft of the rotation drive motor 3 extends into the housing 1 and is equipped with a first gear 4. The vibratory tamping rod body 100 is rotatably mounted on the housing 1. The upper end of the vibratory tamping rod body 100 extends into the housing 1 and is equipped with a second gear 5. The first gear 4 meshes with the second gear 5. The vibratory sleeve 200 is provided with a plurality of gas passage holes 201 (the gas passage holes 201 are very small micropores that only allow gas to pass through, but concrete cannot pass through). A space 15 is formed between the vibratory sleeve 200 and the outside of the vibratory tamping rod body 100. A central air channel 1 extending along its axis is formed inside the vibratory tamping rod body 100. 01. A central air duct 101 extends through the upper end of the vibrator to form an exhaust port. A guide air duct 102 is formed inside the vibrator body 100. One end of the guide air duct 102 is connected to the central air duct 101, and the other end extends through the outside of the vibrator body 100 to connect to the partition space 15. When the small vibrator performs vibration operation on the concrete to be vibrated, the vibrator body 100 and the vibrating sleeve 200 enter the concrete. On the one hand, the vibration drive motor 2 drives the housing 1... Vibration causes the vibrator body 100 and vibrator sleeve 200 to vibrate in the concrete. On the other hand, the rotating drive motor 3 drives the vibrator body and vibrator sleeve 200 to rotate in the concrete, thereby generating negative pressure on the outside of the rotating vibrator sleeve 200. During the vibration process, the gas generated can pass through the gas passage hole 201, the interval space 15, the guide air channel 102, and the central air channel 101 in sequence and finally be discharged from the exhaust hole at the top of the vibrator, avoiding air bubbles that may be generated during the vibration process and are difficult to be discharged.

[0035] According to one embodiment of this application, a vent pipe 6 is provided in the housing 1. The first end of the vent pipe 6 and the exhaust hole are able to be sealed and fitted relative to each other about the axis of the vibrating rod body 100. The second end of the vent pipe 6 extends out of the housing 1, which facilitates the final discharge of gas from the outside of the vibrating sleeve 200 to the outside of the housing 1.

[0036] According to a preferred embodiment of this application, the second end of the air duct 6 is connected to an air suction pump (not shown). The air suction pump can be installed on the housing 1 or not, which greatly facilitates the removal of gas from the concrete outside the vibrating sleeve 200. In addition, an operating handle 7 can be provided on the housing 1. The operating handle 7 can be connected to the housing 1 through a known elastic buffer mechanism (not shown).

[0037] It should be noted that the above embodiments only illustrate preferred embodiments of this application, and their descriptions are relatively specific and detailed, but they should not be construed as limiting this application. It should be pointed out that those skilled in the art can make several modifications and improvements without departing from the concept of this application, such as combining different features in various embodiments, and these should all fall within the protection scope of this application.

Claims

1. A seamless, one-time casting process for the gate head of a ship lock, characterized in that, The process of seamless, one-time casting molding of the lock head includes the following steps: a. Construction preparation and condition assessment: Based on the on-site measured data, it was determined that the backfilling behind the wall had been completed and the settlement of the side piers had stabilized; b. Cancel the wide joint: Cancel the longitudinal construction wide joint reserved between the upper gate head pier and the middle bottom plate, integrate the original segmented middle bottom plate and the wide joint area into a whole casting unit, and cancel the original closing mesh on the inside of the wide joint and the connecting structural steel bars on both sides. c. Adjust the concrete mix proportion: Set the water-cement ratio in the concrete to 0.4, add fly ash and mineral powder to the concrete, and reduce the amount of water-reducing agent. d. Pre-embedded cooling water pipes: Cooling water pipes are installed inside the base plate; e. One-time concrete pouring: pour concrete in layers from bottom to top, with each layer less than or equal to 30cm thick and each layer taking less than or equal to 2 hours to pour; pour concrete symmetrically from both sides of the gate head towards the middle, using a vibrator for compaction, with a compaction interval of ≤30cm and a compaction time of 20 to 30 seconds. f. Active temperature control measures: After the concrete is poured, circulating water is introduced into the cooling water pipes; g. Demolding and curing: After the demolding strength is reached, remove the formwork, cover it with a moisturizing and curing layer, and cure it by sprinkling or running water for no less than 14 days. h. Acceptance: Conduct tests on appearance, strength, density, and leakage. Once the tests are passed, proceed with subsequent construction.

2. The seamless, one-time casting process for the lock head as described in claim 1, characterized in that, In step a, a high-precision hydrostatic level and a GNSS displacement monitoring station are used to monitor the settlement of the pier. Data is automatically collected at a frequency of no less than once per hour and uploaded to the cloud central control platform in real time. The cloud central control platform automatically calculates the diurnal average settlement rate over 30 days. When the diurnal average settlement rate is less than 0.1 mm and this condition is met for no less than 3 consecutive days, the cloud central control platform generates a "stabilized pier settlement" judgment information and pushes the "stabilized pier settlement" judgment information to the management terminal equipment.

3. The seamless, one-time casting process for the lock head as described in claim 1, characterized in that, The concrete mix proportion in step c is generated by the following method: a raw material performance database is established, on-site environmental parameters are collected, the water-cement ratio of 0.4 is taken as the target, the fly ash content, mineral powder content, water-reducing agent content, and sand ratio are optimized variables, and the slump, initial setting time, strength, and heat of hydration are used as constraints. The optimal construction mix proportion is automatically generated by genetic algorithm or Bayesian optimization and sent to the mixing plant.

4. The seamless, one-time casting process for the lock head as described in claim 1, characterized in that, In step f, the cooling water flow rate and water temperature are automatically adjusted based on the real-time feedback data from the pre-embedded temperature sensor. When the internal and external temperature difference is <20℃, the current flow rate and water temperature are maintained; when the internal and external temperature difference is 20℃~23℃, the flow rate is increased by 0.2m³ / h; when the internal and external temperature difference is 23℃~24.5℃, the flow rate is increased to 1.5m³ / h and the water temperature is reduced by 2℃; when the internal and external temperature difference is ≥24.5℃, the flow rate is adjusted to the maximum value of 2.0m³ / h, the water temperature is reduced to the minimum allowable value, and an orange warning is issued; when the internal and external temperature difference is ≥25℃, a red alarm is issued and the circulation is forcibly increased; after the internal and external temperature difference falls back below 20℃, the flow rate is gradually reduced and the water temperature is increased, controlling the cooling rate to ≤2℃ / d.

5. The seamless, one-time casting process for the lock head as described in claim 1, characterized in that, The moisturizing layer described in step g has multiple distributed optical fiber humidity sensors arranged in sequence. The spacing between adjacent distributed optical fiber humidity sensors is 1m to 3m to monitor the humidity in the moisturizing layer in real time. When any distributed optical fiber humidity sensor detects that the humidity is lower than 92%RH, the humidity in the moisturizing layer is restored to above 95%RH by spraying.

6. The seamless, one-time casting process for the lock head of a ship lock according to any one of claims 1 to 5, characterized in that, Step e also includes: using a small vibrator to vibrate the concrete at the edge of the formwork between the formwork and the reinforcing bars to remove air bubbles at the edge of the formwork.

7. A seamless, one-time casting system for lock head, characterized in that, The seamless one-time casting system for the lock head is used to implement the seamless one-time casting process for the lock head as described in claim 6. The seamless one-time casting system for the lock head includes: The concrete supply system includes a batching plant, concrete mixer trucks, and pumping equipment. Template system; Cooling water piping system, including cooling water pipes embedded in the base plate; Temperature monitoring system, including a temperature sensor installed in the cooling water pipe; Vibration device, including vibrator and small vibrating rod; The system includes a main controller, a high-precision hydrostatic level, a GNSS displacement monitoring station, and a cloud-based central control platform. The main controller is connected to the high-precision hydrostatic level, the GNSS displacement monitoring station, the cloud-based central control platform, the cooling water pipeline system, and the temperature monitoring system.

8. The seamless, one-time casting system for lock head as described in claim 7, characterized in that, The small vibratory rod includes a shell, a vibration drive motor, a rotation drive motor, a vibratory rod body, and a vibratory sleeve disposed on the outside of the vibratory rod body. The vibration drive motor is mounted on the shell to drive the shell to vibrate. The rotation drive motor is mounted on the shell, and the output shaft of the rotation drive motor extends into the shell and is equipped with a first gear. The vibratory rod body is rotatably mounted on the shell, and the upper end of the vibratory rod body extends into the shell and is equipped with a second gear. The first gear meshes with the second gear. The vibratory sleeve is provided with multiple gas passage holes. A space is formed between the vibratory sleeve and the outside of the vibratory rod body. A central air passage extending along its axis is formed inside the vibratory rod body. The central air passage extends through the upper end of the vibratory rod to form an exhaust hole. A guide air passage is formed inside the vibratory rod body. One end of the guide air passage is connected to the central air passage, and the other end of the guide air passage extends out of the outside of the vibratory rod body and connects to the space.

9. The seamless, one-time casting system for lock heads according to claim 8, characterized in that, The housing is provided with an air guide tube, the first end of the air guide tube and the exhaust hole are able to be sealed and fitted relative to each other about the axis of the vibrating rod body, and the second end of the air guide tube extends out of the housing.

10. The seamless, one-time casting system for lock head as described in claim 9, characterized in that, The second end of the air duct is connected to an air pump.

Images