Foundation digging and vertical reinforcement cage forming integrated machine and construction method

Abstract

The application discloses a foundation digging and vertical steel reinforcement cage forming integrated machine and a construction method, which comprises a bottom support, a first winch, a foundation auxiliary digging and hole forming module and a vertical steel reinforcement cage forming module. The first winch is arranged on the bottom support, and the foundation auxiliary digging and hole forming module and the vertical steel reinforcement cage forming module are selectively detachably installed on the bottom support. When the foundation auxiliary digging and hole forming module is installed on the bottom support, the first winch serves as a counterweight and an emergency lifting device to perform a foundation digging operation. When the vertical steel reinforcement cage forming module is installed on the bottom support, the first winch serves as a lifting and lowering device of the steel reinforcement cage to perform a vertical steel reinforcement cage forming and in-situ installation operation. The application realizes functional reuse of the bottom support and the first winch in two core processes of digging and hole forming and steel reinforcement cage forming through modular design, and improves equipment utilization and construction efficiency.

Description

Technical Field

[0001] This invention relates to the field of pile foundation construction equipment technology, and in particular to an integrated machine and construction method for foundation excavation and vertical steel cage forming. Background Technology

[0002] Cut-and-cover foundations (such as manually excavated bored piles) are widely used in power transmission towers, bridges, and building construction. The traditional construction process for cut-and-cover piles is usually divided into two main stages: the first stage is the excavation of the foundation pit, and the second stage is the binding and lowering of the reinforcing cage.

[0003] The existing construction methods have the following drawbacks in these two stages: First, low equipment utilization and cumbersome relocation. Excavation typically uses independent tripod-mounted soil-lifting equipment, which needs to be dismantled after drilling. Then, a large crane or a specialized horizontal rigging frame must be erected for rebar cage construction. Frequent dismantling and relocation of equipment is time-consuming and labor-intensive. Second, the quality and efficiency of rebar cage formation are difficult to guarantee. After traditional horizontal rebar cage rigging, it needs to be lifted, turned over, and lowered back into the hole, which not only easily causes deformation but also poses significant safety hazards during secondary handling. Third, high safety risks in underground operations. During excavation, toxic and harmful gases or oxygen deficiency can easily accumulate inside the hole. Existing equipment often lacks integrated real-time gas monitoring and forced ventilation mechanisms, relying on manual experience and judgment, which can easily lead to safety accidents. Summary of the Invention

[0004] The technical problem to be solved by this invention is to provide an integrated machine and construction method for foundation excavation and vertical steel cage forming, so as to improve equipment utilization and construction efficiency.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A foundation excavation and vertical rebar cage forming integrated machine includes a bottom support, a first winch, a foundation auxiliary excavation and hole-forming module, and a vertical rebar cage forming module. The first winch is mounted on the bottom support, and either the foundation auxiliary excavation and hole-forming module or the vertical rebar cage forming module is detachably installed on the bottom support. When the foundation auxiliary excavation and hole-forming module is installed on the bottom support, the first winch serves as a counterweight and emergency lifting device to perform foundation excavation operations. When the vertical rebar cage forming module is installed on the bottom support, the first winch serves as a hoisting and lowering device for the rebar cage to perform vertical rebar cage forming and in-situ installation operations.

[0006] Furthermore, a construction method is provided, comprising the following steps: S1, installing the foundation auxiliary excavation and hole-forming module of the integrated machine on the bottom support, and using the second winch to raise and lower the hoisting rope, thereby driving the material cylinder to lift and excavate soil via pulleys; S2, after excavation, removing the foundation auxiliary excavation and hole-forming module, retaining the bottom support and the first winch; installing the vertical steel cage forming module, so that the active end support, passive end support, and two auxiliary supports are distributed circumferentially along the pile foundation hole; erecting the inner stirrups on the inner stirrup hoisting structure of the integrated machine, installing the main reinforcement, and adjusting the height of each layer of cross-shaped main reinforcement support structure by rotating the handwheel of the lifting hand crank device to complete the positioning of the steel cage skeleton; S3, starting the equipment, while the first winch drives the steel cage skeleton to be lowered at a uniform speed, the rotating winding structure drives the outer stirrups to spirally wind along the main reinforcement, and the automatic welding structure performs real-time spot welding on the intersection of the main reinforcement and the outer stirrups.

[0007] The beneficial effects of this invention are as follows: By modularly reusing the bottom support and the first winch in the two processes of excavation and hole forming and rebar cage forming, the rapid switching of equipment functions and in-situ connection are realized, avoiding the frequent disassembly and relocation of soil lifting equipment and binding supports in traditional construction, thus improving equipment utilization and overall construction efficiency; at the same time, the vertical rebar cage forming module allows the rebar cage to be directly vertically bound above the pile foundation hole and lowered in-situ, eliminating the secondary handling and turning and lifting links, and further shortening the construction period. Attached Figure Description

[0008] Figure 1 This is a schematic diagram of the basic excavation part of the present invention; Figure 2 This is a schematic diagram of the vertical steel cage forming part of the present invention; Figure 3 This is a schematic diagram of the active end support of the present invention; Figure 4 This is a schematic diagram of the passive end support of the present invention; Figure 5 This is a schematic diagram of the auxiliary support structure of the present invention; Figure 6 This is a schematic diagram of the rotating rib structure of the present invention; Figure 7 This is a schematic diagram of the rotating mechanism in the rotating winding structure of the present invention; Figure 8 This is a schematic diagram of the structure of the hand-cranked device for raising the height of the present invention; Figure 9 This is a schematic diagram of the first-layer cross-shaped main reinforcement support structure of the present invention; Figure 10 This is a schematic diagram of the second-layer cross-shaped main reinforcement support structure of the present invention; Figure 11 This is a schematic diagram of the internal stirrup hoisting structure of the present invention; Figure 12 This is a schematic diagram of the automatic welding structure of the present invention; Figure 13 This is a schematic diagram of the steel cage base structure of the present invention; Figure 14 This is a schematic diagram of the external stirrup placement structure of the present invention.

[0009] Label Explanation: 1. Bottom support; 2. First winch; 3. Second winch; 4. Boom; 5. Pulley; 6. Cylinder; 7. Air supply equipment; 71. Air duct; 8. Gas detection device; 9. Hand winch; 10. Control box; 11. Active end support; 111. Pulley base; 112. Diagonal brace; 12. Passive end support; 121. First column; 122. First base; 123. First diagonal brace; 124. Second diagonal brace; 13. Auxiliary support; 131. Second column; 132. Second base; 133. Third diagonal brace; 134. Reinforcing rib; 14. Rotating winding structure; 141. Rotating track; 142. Rack and pinion track; 143. Rotating mechanism; 1431. Fixed seat; 1432. Bearing assembly; 1433. Drive component; 1434. Pulley block; 1435. Bullseye bearing; 1436. Guide wheel; 1437. Adjusting plate; 1438. Gear; 15. Lifting hand crank device; 151. Base; 152. Screw rod; 153. Handwheel; 154. Protective pipe; 155. Mounting seat; 16. Cross-shaped main reinforcement support structure; 161. Cross support frame; 162. Large formwork ring; 163. Small formwork ring; 164. Main reinforcement clamp; 17. Inner stirrup hoisting structure; 171. Fixing frame; 172. Elastic self-locking pin; 18. Automatic welding structure; 19. Reinforcing cage base structure; 191. Base ring; 192. Lifting ring; 20. Outer stirrup placement structure; 201. Adjustable baffle; 21. Moving pulley; 22. Steel wire rope; 23. Main reinforcement; 24. Outer stirrup. Detailed Implementation

[0010] To explain in detail the technical content, objectives, and effects of the present invention, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0011] Please refer to Figures 1 to 3A foundation excavation and vertical rebar cage forming integrated machine includes a bottom support 1, a first winch 2, a foundation auxiliary excavation and hole-forming module, and a vertical rebar cage forming module. The first winch 2 is installed on the bottom support 1. The foundation auxiliary excavation and hole-forming module and the vertical rebar cage forming module are optionally detachably installed on the bottom support 1. When the foundation auxiliary excavation and hole-forming module is installed on the bottom support 1, the first winch 2 serves as a counterweight and emergency lifting device to perform foundation excavation operations. When the vertical rebar cage forming module is installed on the bottom support 1, the first winch 2 serves as a hoisting and lowering device for the rebar cage to perform vertical rebar cage forming and in-situ installation operations.

[0012] As can be seen from the above description, the beneficial effects of the present invention are as follows: Through modular design, the bottom support and the first winch can be reused in the two core processes of excavation and hole forming and rebar cage forming. In the excavation stage, the first winch serves as a counterweight and emergency lifting device, while in the forming stage, it is directly converted into a power source for hoisting and lowering the rebar cage, avoiding the redundant investment of multiple equipment in traditional construction and reducing construction costs. At the same time, the foundation auxiliary excavation and hole forming module and the vertical rebar cage forming module adopt a selective detachable installation method, realizing the in-situ connection between the excavation and forming processes, greatly reducing the equipment transfer and disassembly time, and shortening the overall construction period. In addition, the rebar cage is directly vertically tied and welded above the pile foundation hole and lowered in situ, completely eliminating the secondary hoisting and turning process, which not only avoids quality problems such as rebar cage deformation and disintegration, but also avoids the risks of hoisting operations in confined spaces.

[0013] Please refer to Figure 1 Furthermore, the basic auxiliary excavation and hole-forming module includes a second winch 3, a boom 4, a pulley 5, and a material cylinder 6; the boom 4 is mounted on the bottom support 1; the second winch 3 is mounted on the end of the boom 4 near the bottom support 1; the pulley 5 is mounted on the end of the boom 4 away from the bottom support 1; the second winch 3 is connected to the pulley 5 and the material cylinder 6 by a hoisting rope.

[0014] As described above, by placing the second winch at the end of the boom near the bottom support, the overall center of gravity of the excavation module is lowered, improving the equipment's anti-overturning ability during soil lifting operations and further optimizing the overall counterweight effect in conjunction with the bottom support and the first winch. At the same time, placing the pulley at the cantilever end of the boom away from the bottom support allows the material cylinder to be precisely suspended above the pile hole, ensuring the verticality of the soil lifting process and preventing the material cylinder from scraping against the hole wall.

[0015] Please refer to Figure 1Furthermore, the basic auxiliary excavation and hole-forming module also includes an air supply device 7, a gas detection device 8, and a hand-cranked winch 9; the air supply device 7 has an air duct 71 that extends into the pile foundation hole to supply air to the inside of the pile foundation hole; the gas detection device 8 is connected to the hand-cranked winch 9 and extends into the pile foundation hole to detect the air inside the pile foundation hole.

[0016] As described above, by installing air supply equipment and extending the air duct into the pile foundation borehole, fresh air can be continuously supplied to the bottom of the deep hole, effectively expelling harmful gases, dust, and oxygen-deficient air accumulated in the hole, providing a safe breathing environment for subsequent manual entry operations. At the same time, the gas detection device is connected to the hand-cranked winch and extends into the hole, which can monitor key safety indicators such as oxygen concentration and toxic and harmful gas content in the hole in real time before personnel enter and during the operation.

[0017] Please refer to Figure 1 Furthermore, the boom 4 is mounted on the bottom support 1 via a rotating support.

[0018] As described above, the boom is mounted on the bottom support via a rotating support, allowing the boom to rotate flexibly in the horizontal plane. This enables precise adjustment of the suspension position of the material cylinder during excavation operations to meet the alignment requirements of different pile foundation holes.

[0019] Please refer to Figures 2 to 5 Furthermore, the vertical rebar cage forming module includes a pulley base 111, a diagonal support rod 112, a movable pulley 21, a wire rope 22, a passive end support 12, and an auxiliary support 13. The pulley base 111 is set on the bottom support 1, and the diagonal support rod 112 connects the pulley base 111 and the bottom support 1 respectively. The bottom support 1, the pulley base 111, the first winch 2, and the diagonal support rod 112 together form the active end support 11. The active end support 11 and the passive end support 12 are arranged opposite to each other, and the wire rope 22 connects the active end support 11 and the passive end support 12 respectively. The movable pulley 21 is set on the wire rope 22. There are two auxiliary supports 13 arranged opposite to each other, and the auxiliary supports 13 are distributed circumferentially between the active end support 11 and the passive end support 12 along the pile foundation hole. Preferably, the angle between the active end support 11 and the passive end support 12 and the adjacent auxiliary support 13 is 90 degrees.

[0020] As described above, the active end support, passive end support, and two auxiliary supports are approximately orthogonally symmetrically distributed around the pile foundation hole, thus providing uniform and symmetrical lateral restraint forces from four directions during the vertical forming process of the steel cage, preventing the steel cage from eccentric bending or torsional instability due to its own weight or construction disturbance.

[0021] Please refer to Figure 4Furthermore, the passive end support 12 includes a first column 121, a first base 122, a first diagonal brace 123, and a second diagonal brace 124; the first column 121 is bolted to the first base 122; one end of the first diagonal brace 123 is bolted to the first base 122, and the other end is pinned to the first column 121; the first column 121, the first base 122, and the first diagonal brace 123 form a triangular shape; inside the triangle, one end of the second diagonal brace 124 is bolted to the first base 122, and the other end is pinned to the first column 121.

[0022] Please refer to Figure 5 Furthermore, the auxiliary support 13 includes a second column 131, a second base 132, a third diagonal brace 133, and a reinforcing rib 134; the second column 131 is bolted to the second base 132; one end of the third diagonal brace 133 is bolted to the second base 132, and the other end is pinned to the second column 131; the second column 131, the second base 132, and the third diagonal brace 133 form a triangular shape; the reinforcing rib 134 is disposed between the second column 131 and the second base 132.

[0023] As described above, the triangular structure enhances the overall structural stiffness and anti-overturning capacity of the passive end support and auxiliary support, enabling them to reliably withstand the enormous lateral tensile force and bending moment generated during wire rope tensioning and steel cage hoisting. The addition of a second diagonal brace or reinforcing rib inside the triangle further disperses the stress concentration at the connection node between the column and the base.

[0024] Please refer to Figure 6 as well as Figure 7 Furthermore, the vertical rebar cage forming module also includes a rotating winding structure 14, which is connected to the active end support 11, the passive end support 12, and the auxiliary support 13. The rotating winding structure 14 includes a rotating track 141, a rack track 142, and a rotating mechanism 143. In the height direction of the vertical rebar cage forming module, the rotating track 141 is horizontally positioned above the rack track 142. The gear 1438 of the rotating mechanism 143 meshes with the rack of the rack track 142. The rotating mechanism 143 is slidably connected to the rotating track 141.

[0025] As described above, the rotating rebar winding structure forms a closed-loop operating platform around the rebar cage forming area by connecting the active end support, the passive end support, and the auxiliary support, enabling the rebar winding operation to be carried out continuously along the circumference of the rebar cage. The rotating track is horizontally set above the rack track, providing a stable guide and load-bearing benchmark for the rotating mechanism and ensuring its positioning accuracy in the height direction. The gears of the rotating mechanism mesh with the rack track to achieve mechanized automatic movement of the rebar winding operation.

[0026] Please refer to Figure 6 Furthermore, both the rotary track 141 and the rack track 142 are composed of four quarter-circular rings, and each ring is bolted to the active end support 11, the passive end support 12 and the two auxiliary supports 13 respectively, and the rings are connected to each other by connecting plates.

[0027] As described above, the quarter ring is easy to transport, and when a section of the track is worn or damaged, the corresponding ring can be disassembled and replaced individually without the need for the entire track to be scrapped, thus reducing maintenance costs and downtime.

[0028] Please refer to Figure 7 Furthermore, the rotating mechanism 143 includes a fixed base 1431, a bearing assembly 1432, a driving member 1433, and a pulley assembly 1434; the fixed base 1431 is slidably connected to the rotating track 141 through the bearing assembly 1432; the driving member 1433 is disposed on the fixed base 1431 and is connected to the gear 1438 for transmission; the pulley assembly 1434 is disposed on the fixed base 1431, and the outer hoop 24 abuts against the pulley assembly 1434; preferably, the rotating mechanism 143 also includes a bullseye bearing 1435 and a guide wheel 1436, the bearing assembly 1432 is provided with upper and lower mating sides of the bullseye bearing 1435 which are clamped together on the rotating track 141, and the guide wheel 1436 is disposed on one side of the fixed base 1431 for guiding the outer hoop 24.

[0029] As described above, the rotating mechanism achieves a low-friction, high-precision sliding connection with the rotating track through the bearing assembly, ensuring the stability and guiding reliability of the fixed seat when running on the circular track, and reducing motion resistance and wear; the pulley assembly is set on the fixed seat and abuts against the outer hoop, which not only provides stable radial support and tension control for the outer hoop, preventing it from shifting or loosening during winding, but also reduces frictional damage between it and the steel bar through rolling contact.

[0030] Please refer to Figure 7 Furthermore, the rotating mechanism 143 also includes an adjusting plate 1437, which is mounted on the fixed base 1431, and the pulley block 1434 is mounted on the adjusting plate 1437.

[0031] As described above, the adjusting plate is used to adjust the stroke according to the size of the steel cage on site, so as to realize the winding of the outer stirrups of steel cages of different sizes.

[0032] Please refer to Figures 8 to 10Furthermore, it also includes at least two layers of cross-shaped main reinforcement support structures 16 and four lifting hand cranks 15; the lifting hand crank 15 includes a base 151, a lead screw 152 and a handwheel 153; the base 151 is connected to the active end support 11, the passive end support 12 and the auxiliary support 13; the handwheel 153 is disposed on the base 151 and is connected to the lead screw 152 in a transmission connection; one layer of cross-shaped main reinforcement support structure 16 is connected to the base 151, and the other layer of cross-shaped main reinforcement support structure 16 is connected to the end of the lead screw 152 away from the base 151; preferably, the lifting hand crank 15 also includes a protective tube 154 and a mounting seat 155, the protective tube 154 is connected to the base 151 and is sleeved on the lead screw 152, and the mounting seat 155 is connected to one end of the lead screw 152 and the cross-shaped main reinforcement support structure 16 respectively.

[0033] As described above, at least two layers of cross-shaped main reinforcement support structure are arranged vertically and are height-adjustable through a lifting hand crank device. This can adapt to the positioning requirements of main reinforcement cages with different diameters and reinforcement requirements, ensuring that the main reinforcement maintains accurate radial position and verticality during the vertical forming process.

[0034] Please refer to Figure 9 as well as Figure 10 Furthermore, the cross-shaped main reinforcement support structure 16 includes a cross support frame 161, a large template ring 162, a small template ring 163, and a main reinforcement clamp 164; the first layer of the cross support frame 161 is bolted to the base 151, and the second layer of the cross support frame 161 is bolted to the mounting base 155; the large template ring 162 and the small template ring 163 are fixedly connected to the cross support frame 161, and the main reinforcement clamp 164 is evenly arranged around the circumference of the large template ring 162 or the small template ring 163.

[0035] As can be seen from the above description, large or small template rings can be flexibly used for steel cages of different sizes, and the main reinforcement clamps are evenly arranged along the circumference of the template ring, so that each main reinforcement can be independently clamped and radially limited.

[0036] Please refer to Figure 11 Furthermore, it also includes an inner stirrup hoisting structure 17, on which the inner stirrups are erected; the active end support 11, the passive end support 12 and the two auxiliary supports 13 are all provided with inner stirrup hoisting structures 17; specifically, the inner stirrup hoisting structure 17 includes a fixing frame 171 and elastic self-locking pins 172, the fixing frame 171 is connected to the four supports, and several elastic self-locking pins 172 are set on the fixing frame 171 along the height direction of the vertical steel cage forming module, and the inner stirrups are erected on the elastic self-locking pins 172.

[0037] As can be seen from the above description, the elastic self-locking pin has both load-bearing and self-locking functions, and can automatically limit the position after the inner stirrups are erected to prevent slippage or displacement.

[0038] Please refer to Figure 12 Furthermore, it also includes an automatic welding structure 18, which is mounted on the active end support 11, the passive end support 12, or the auxiliary support 13. The automatic welding structure 18 uses existing automatic welding equipment.

[0039] Please refer to Figure 13 Furthermore, it also includes a steel cage base structure 19, which includes a base ring 191 and lifting rings 192. The base ring 191 needs to be customized in size according to the parameters of the steel cage, bent into a circle and welded according to requirements, and processed with round holes that conform to the number and distribution position of the main reinforcement 23 of the steel cage. The size of the round holes is larger than the maximum outer diameter of the main reinforcement 23. The lifting rings 192 are evenly distributed on the base ring 191.

[0040] As described above, the steel cage base structure serves as the bottom positioning reference and the overall hoisting load-bearing carrier during the vertical forming process. Its customized design ensures precise matching with steel cages of specific specifications.

[0041] Please refer to Figure 14 Furthermore, it also includes an outer stirrup placement structure 20, which consists of four identical adjustable baffles 201 installed on the inner side below the four supports. When installing the outer stirrups 24, they must be inserted into the ring formed by the four identical adjustable baffles 201 in a clockwise direction.

[0042] As can be seen from the above description, the structure cleverly utilizes the unused space under the support, which neither interferes with the positioning of the upper main reinforcement and the hoisting of the inner stirrups, nor does it interfere with the outer stirrups.

[0043] Please refer to Figures 1 to 14 Furthermore, a construction method using the aforementioned integrated machine is provided, comprising the following steps: S1, installing the foundation auxiliary excavation and hole-forming module of the integrated machine onto the bottom support 1, and using the second winch 3 to raise and lower the hoisting rope, thereby driving the material cylinder 6 to rise and fall via the pulley 5 for soil excavation; S2, after excavation is completed, removing the foundation auxiliary excavation and hole-forming module, retaining the bottom support 1 and the first winch 2; installing the vertical steel cage forming module, so that the active end support 11, the passive end support 12, and the two auxiliary supports 13 are distributed circumferentially along the pile foundation hole position. The inner stirrups are erected on the inner stirrup hoisting structure 17 in the integrated machine, the main reinforcement 23 is installed, and the screw rod 152 is driven to rise and fall by rotating the handwheel 153 of the lifting hand crank device 15 to adjust the height of the cross-shaped main reinforcement support structure 16 of each layer, thus completing the positioning of the steel cage skeleton; S3, start the equipment, the first winch 2 drives the steel cage skeleton to be lowered at a uniform speed, while the rotating winding structure 14 drives the outer stirrups 24 to spirally wind along the main reinforcement 23, and the automatic welding structure 18 performs real-time spot welding on the intersection of the main reinforcement 23 and the outer stirrups 24.

[0044] As can be seen from the above description, this construction method achieves seamless connection of the two key processes of pile foundation drilling and steel cage forming on the same equipment platform through the operation mode of multi-purpose machine and modular switching, reducing the time loss and cost input caused by the entry, transfer and repeated positioning of multiple equipment in traditional construction.

[0045] Please refer to Figures 1 to 14 Embodiment 1 of the present invention is as follows: An integrated machine for foundation excavation and vertical rebar cage forming includes a bottom support 1, a first winch 2, a foundation auxiliary excavation and hole-forming module, and a vertical rebar cage forming module. The first winch 2 is mounted on the bottom support 1. Either the foundation auxiliary excavation and hole-forming module or the vertical rebar cage forming module is detachably installed on the bottom support 1. When the foundation auxiliary excavation and hole-forming module is installed on the bottom support 1, the first winch 2 serves as a counterweight and emergency lifting device for foundation excavation operations. When the vertical rebar cage forming module is installed on the bottom support 1, the first winch 2 serves as a hoisting and lowering device for the rebar cage to perform vertical rebar cage forming and in-situ installation operations.

[0046] In this embodiment, the basic auxiliary excavation and hole-forming module includes a second winch 3, a boom 4, a pulley 5, a material cylinder 6, an air supply device 7, a gas detection device 8, a hand-cranked winch 9, and a control box 10. The boom 4 is mounted on the bottom support 1 via a rotating support, allowing the boom 4 to rotate flexibly in the horizontal plane. The second winch 3 is located at the end of the boom 4 near the bottom support 1, and the pulley 5 is located at the cantilever end of the boom 4 away from the bottom support 1. The second winch 3 is connected to the pulley 5 and the material cylinder 6 via a hoisting rope. The air supply device 7 has an air duct 71 that extends into the pile foundation hole to supply air to the inside of the pile foundation hole. The gas detection device 8 is connected to the hand-cranked winch 9 and extends into the pile foundation hole to detect the internal air in the pile foundation hole. During the excavation process, the second winch 3 raises and lowers the hoisting rope to drive the material cylinder 6 to lift and excavate soil via the pulley 5. At the same time, the air supply equipment 7 continuously supplies air into the pile foundation hole, and the height of the gas detection device 8 is adjusted by the hand-cranked winch 9 to detect air safety indicators in real time. The control box 10 is used to control the equipment of the foundation auxiliary excavation hole-forming module.

[0047] After excavation is completed, the foundation auxiliary excavation and hole-forming module is removed, leaving the bottom support 1 and the first winch 2 intact. The vertical rebar cage forming module is then installed. The vertical rebar cage forming module includes a pulley base 111, a diagonal support rod 112, a movable pulley 21, a wire rope 22, a passive end support 12, an auxiliary support 13, a rotating rebar winding structure 14, four lifting hand cranks 15, a two-layer cross-shaped main rebar support structure 16, an inner stirrup hoisting structure 17, an automatic welding structure 18, a rebar cage base structure 19, and an outer stirrup placement structure 20. The pulley base 111 is mounted on the bottom support 1, and the diagonal support rod 112 connects the pulley base 111 and the bottom support 1 respectively. The bottom support 1, the pulley base 111, the first winch 2, and the diagonal support rod 112 together form the active end support 11. The active end support 11 and the passive end support 12 are arranged opposite to each other. A steel wire rope 22 connects the active end support 11 and the passive end support 12 respectively, and a movable pulley 21 is arranged on the steel wire rope 22. Two auxiliary supports 13 are distributed circumferentially between the active end support 11 and the passive end support 12 along the pile foundation hole. The angle between the active end support 11 and the passive end support 12 and the adjacent auxiliary support 13 is 90 degrees.

[0048] In this embodiment, the passive end support 12 includes a first column 121, a first base 122, a first diagonal brace 123, and a second diagonal brace 124. The first column 121 is bolted to the first base 122. One end of the first diagonal brace 123 is bolted to the first base 122, and the other end is pinned to the first column 121. The first column 121, the first base 122, and the first diagonal brace 123 form a triangular shape. Inside the triangle, one end of the second diagonal brace 124 is bolted to the first base 122, and the other end is pinned to the first column 121.

[0049] In this embodiment, the auxiliary support 13 includes a second column 131, a second base 132, a third diagonal brace 133, and a reinforcing rib 134. The second column 131 is bolted to the second base 132. One end of the third diagonal brace 133 is bolted to the second base 132, and the other end is pinned to the second column 131. The second column 131, the second base 132, and the third diagonal brace 133 form a near-triangular shape. The reinforcing rib 134 is disposed between the second column 131 and the second base 132.

[0050] In this embodiment, the rotating reinforcing bar structure 14 is connected to the active end support 11, the passive end support 12, and the auxiliary supports 13. The rotating reinforcing bar structure 14 includes a rotating track 141, a rack track 142, and a rotating mechanism 143. In the height direction of the vertical reinforcing bar cage forming module, the rotating track 141 is horizontally positioned above the rack track 142. Both the rotating track 141 and the rack track 142 consist of four quarter-circular rings. Each ring is bolted to the active end support 11, the passive end support 12, and the two auxiliary supports 13, and the rings are connected to each other by connecting plates. The rotating mechanism 143 includes a fixed base 1431, a bearing assembly 1432, a driving component 1433, a pulley assembly 1434, a bullseye bearing 1435, a guide wheel 1436, and an adjusting plate 1437. The fixed base 1431 is slidably connected to the rotating track 141 via a bearing assembly 1432. The bearing assembly 1432 has two layers of bullseye bearings 1435 on its mating sides, which together clamp the rotating track 141. The driving component 1433 is mounted on the fixed base 1431 and is connected to the gear 1438 for transmission. The gear 1438 meshes with the rack of the rack track 142. An adjusting plate 1437 is provided on the fixed base 1431. A pulley assembly 1434 is mounted on the adjusting plate 1437 and abuts against the outer hoop 24. A guide wheel 1436 is located on one side of the fixed base 1431 to guide the outer hoop 24.

[0051] In this embodiment, the lifting hand crank device 15 includes a base 151, a lead screw 152, a handwheel 153, a protective tube 154, and a mounting base 155. The base 151 is connected to the active end support 11, the passive end support 12, and the auxiliary support 13. The handwheel 153 is disposed on the base 151 and is connected to the lead screw 152 for transmission. The protective tube 154 is connected to the base 151 and sleeved on the lead screw 152. One layer of cross-shaped main rib support structure 16 is bolted to the base 151, and another layer of cross-shaped main rib support structure 16 is bolted to the end of the lead screw 152 away from the base 151 through the mounting base 155.

[0052] In this embodiment, the cross-shaped main reinforcement support structure 16 includes a cross support frame 161, a large template ring 162, a small template ring 163, and a main reinforcement clamp 164. The large template ring 162 and the small template ring 163 are fixedly connected to the cross support frame 161, and the main reinforcement clamp 164 is evenly arranged around the circumference of the large template ring 162 or the small template ring 163.

[0053] In this embodiment, the inner stirrup hoisting structure 17 includes a fixing frame 171 and elastic self-locking pins 172. The fixing frame 171 is connected to four supports, and several elastic self-locking pins 172 are set on the fixing frame 171 along the height direction of the vertical steel cage forming module. The inner stirrups are laid on the elastic self-locking pins 172.

[0054] In this embodiment, the automatic welding structure 18 is mounted on the active end support 11, the passive end support 12, or the auxiliary support 13.

[0055] In this embodiment, the reinforcing cage base structure 19 includes a base ring 191 and lifting rings 192. The base ring 191 is customized in size according to the parameters of the reinforcing cage and has round holes that conform to the number and distribution position of the main reinforcing bars 23. The lifting rings 192 are evenly distributed on the base ring 191.

[0056] In this embodiment, the outer hoop placement structure 20 is composed of four identical adjustable baffles 201, which are respectively installed on the inner side below the four supports.

[0057] Please refer to Figures 1 to 14 Embodiment two of the present invention is as follows: A construction method for a foundation excavation and vertical rebar cage forming integrated machine is provided. First, the foundation auxiliary excavation and hole forming module of the integrated machine is installed on the bottom support 1. The second winch 3 is used to raise and lower the hoisting rope, which drives the material cylinder 6 to be raised and lowered via the pulley 5 to excavate soil. During the excavation process, the air supply device 7 continuously supplies air into the pile foundation hole through the air duct 71. At the same time, the height of the gas detection device 8 is adjusted by the hand winch 9 to detect the air safety index inside the pile foundation hole in real time. After excavation is completed, the foundation auxiliary excavation and hole-forming module is removed, while the bottom support 1 and the first winch 2 are retained. The vertical steel cage forming module is installed, so that the active end support 11, the passive end support 12, and the two auxiliary supports 13 are distributed at a 90-degree angle along the circumference of the pile hole. The inner stirrups are placed on the elastic self-locking pins 172 of the inner stirrup hoisting structure 17 in the integrated machine. The main reinforcement 23 is installed, and the height of the cross-shaped main reinforcement support structure 16 of each layer is adjusted by rotating the handwheel 153 of the lifting hand crank device 15 to drive the screw 152 to rise and fall, so that the main reinforcement 23 is fixed in the main reinforcement clamp 164, thus completing the positioning of the steel cage skeleton. Then the equipment is started. The first winch 2 drives the steel cage frame to be lowered at a uniform speed. At the same time, the drive component 1433 of the rotating winding structure 14 drives the gear 1438 to move on the rack track 142, so that the rotating mechanism 143 slides along the rotating track 141 and drives the outer hoop 24 to spirally wind along the main bar 23. The automatic welding structure 18 performs real-time spot welding on the intersection of the main bar 23 and the outer hoop 24, and finally completes the vertical steel cage forming and in-situ installation operation.

[0058] In summary, the present invention provides an integrated machine and construction method for foundation excavation and vertical rebar cage forming. Through a modular and detachable design, the foundation auxiliary excavation module and the vertical rebar cage forming module can be selectively installed on the same bottom support, achieving seamless integration and equipment reuse between the two major processes of excavation and rebar cage forming and in-situ installation. During the excavation stage, a second winch, in conjunction with a material drum and pulleys, completes the soil lifting operation, while integrated ventilation equipment and gas detection devices ensure safety during operations within the borehole. During the rebar cage forming stage, the bottom support and the first winch are retained as the core support and hoisting power source. A stable annular frame is constructed through active end supports, passive end supports, and auxiliary supports. A lifting hand crank precisely adjusts the height of the cross-shaped main reinforcement support structure to position the main reinforcement skeleton. Then, a rotating winding structure drives the outer stirrups to spirally wind along the main reinforcement, and an automatic welding structure provides real-time spot welding fixation. Finally, with the synchronous lowering of the first winch, the vertical forming and in-situ installation of the rebar cage are completed. This integrated machine solves the problems of cumbersome site transfer, large site occupation, and low efficiency of process connection caused by the separation of excavation equipment and steel cage processing equipment in traditional construction. It improves the overall efficiency of pile foundation construction, while reducing equipment investment costs and labor intensity.

[0059] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent modifications made based on the content of the present invention specification and drawings, or direct or indirect applications in related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A machine integrating foundation excavation and vertical rebar cage forming, characterized in that, Includes bottom support, first winch, foundation auxiliary excavation and hole forming module and vertical steel cage forming module; The first winch is installed on the bottom support, and either the foundation auxiliary excavation and hole forming module or the vertical steel cage forming module is detachably installed on the bottom support. When the basic auxiliary excavation and hole-forming module is installed on the bottom support, the first winch serves as a counterweight and emergency lifting device to perform the basic excavation operation; When the vertical steel cage forming module is installed on the bottom support, the first winch serves as the hoisting and lowering equipment for the steel cage, in order to perform the vertical steel cage forming and in-situ installation operations.

2. The integrated machine for foundation excavation and vertical rebar cage forming according to claim 1, characterized in that, The basic auxiliary excavation and hole-forming module includes a second winch, a boom, pulleys, and a material cylinder; The boom is mounted on the bottom support; The second winch is located at one end of the boom near the bottom support; The pulley is located on the end of the boom away from the bottom support; The second winch connects the pulley and the drum via a hoisting rope.

3. The integrated machine for foundation excavation and vertical rebar cage forming according to claim 2, characterized in that, The basic auxiliary excavation and hole-forming module also includes air supply equipment, gas detection device and hand-cranked winch; The air supply equipment has an air duct that extends into the pile foundation hole to supply air to the inside of the pile foundation hole; The gas detection device is connected to the hand-cranked winch and extends into the pile foundation borehole to detect the internal air in the borehole.

4. The integrated machine for foundation excavation and vertical rebar cage forming according to claim 1, characterized in that, The vertical steel cage forming module includes a pulley base, a diagonal support rod, a movable pulley, a wire rope, a passive end support, and an auxiliary support; The pulley base is mounted on the bottom support, and the inclined support rod connects the pulley base and the bottom support respectively; The bottom support, the pulley base, the first winch, and the inclined support rod together form the active end support; The active end support and the passive end support are arranged opposite to each other, the wire rope connects the active end support and the passive end support respectively, and the movable pulley is arranged on the wire rope; The auxiliary support has two oppositely arranged supports, and the auxiliary supports are distributed circumferentially between the active end support and the passive end support along the pile foundation hole.

5. The integrated machine for foundation excavation and vertical rebar cage forming according to claim 4, characterized in that, The vertical steel cage forming module also includes a rotating winding structure, which is connected to the active end support, the passive end support and the auxiliary support; The rotating winding structure includes a rotating track, a rack track, and a rotating mechanism; In the height direction of the vertical steel cage forming module, the rotating track is horizontally positioned above the rack track; The gear of the rotating mechanism is meshed with the rack of the rack track; The rotating mechanism is slidably connected to the rotating track.

6. The integrated machine for foundation excavation and vertical rebar cage forming according to claim 5, characterized in that, The rotating mechanism includes a fixed base, a bearing assembly, a driving component, and a pulley assembly; The fixed base is slidably connected to the rotating track via the bearing assembly; The driving component is mounted on the fixed base and is connected to the gear transmission; The pulley block is mounted on the fixed base, and the outer hoop abuts against the pulley block.

7. The integrated machine for foundation excavation and vertical rebar cage forming according to claim 6, characterized in that, It also includes at least two layers of cross-shaped main reinforcement support structure and four lifting hand crank devices; The lifting hand crank device includes a base, a lead screw, and a handwheel; The base is connected to the active end support, the passive end support, and the auxiliary support; The handwheel is mounted on the base and is connected to the lead screw drive. The first layer of the cross-shaped main rib support structure is connected to the base, and the first layer of the cross-shaped main rib support structure is connected to the end of the lead screw away from the base.

8. The integrated machine for foundation excavation and vertical rebar cage forming according to claim 7, characterized in that, It also includes an inner stirrup hoisting structure, on which the inner stirrups are erected; The active end support, the passive end support, and the two auxiliary supports are all equipped with the inner stirrup hoisting structure.

9. The integrated machine for foundation excavation and vertical rebar cage forming according to claim 8, characterized in that, It also includes an automatic welding structure, which is disposed on the active end support, the passive end support or the auxiliary support.

10. A construction method for an integrated machine as described in any one of claims 1-9, characterized in that, Includes the following steps: S1. Install the basic auxiliary excavation and hole-forming module in the integrated machine on the bottom support, and use the second winch to wind and unwind the hoisting rope to drive the material cylinder to rise and fall via the pulley for soil excavation. S2. After the excavation is completed, the foundation auxiliary excavation and hole-forming module is removed, while the bottom support and the first winch are retained; the vertical steel cage forming module is installed, so that the active end support, the passive end support and the two auxiliary supports are distributed circumferentially along the pile foundation hole position; the inner stirrups are erected on the inner stirrup hoisting structure in the integrated machine, the main reinforcement is installed, and the screw is driven to lift by rotating the handwheel of the lifting hand crank to adjust the height of the cross-shaped main reinforcement support structure of each layer, thereby completing the positioning of the steel cage skeleton; S3. Start the equipment. The first winch drives the steel cage frame to be lowered at a uniform speed. At the same time, the rotating winding structure drives the outer stirrups to spirally wind along the main reinforcement. The automatic welding structure performs real-time spot welding on the intersection of the main reinforcement and the outer stirrups.

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