A cyclic pulsating bridge pier column concrete super-high pumping device, system and method
Patent Information
- Application Number
- CN202610521597.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-04-20
- Publication Date
- 2026-10-30
AI Technical Summary
(1)智能性不足,无法对泵送过程进行精确控制;
1、本发明通过电动伸缩机构带动四个活塞联动,通过四个活塞的联动效应,实现了高性能混凝土循环往复的脉冲式泵送,为高空输送混凝土提供了新的解决方案。
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Figure CN123005809A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of concrete conveying equipment technology, specifically to a circulating pulsed ultra-high concrete pumping device, system, and method for bridge piers. Background Technology
[0002] During the construction of bridge piers, ultra-high pressure pumping devices are required to deliver high-performance concrete to the required height. Currently, there are few ultra-high pressure pumping methods in China, pumping systems are lacking, conventional pumping processes are imperfect, concrete pumping is uncontrollable, and incidents such as insufficient pumping pressure and pipe blockage during high-rise pumping are very likely to occur.
[0003] Examples of existing technical solutions: In conventional super high-rise construction projects, ultra-high pressure pumps and relay pumping methods are commonly used. For example, patent number CN115680285A, "A Super High-Rise Concrete Pumping System and Construction Method," uses an ultra-high pressure pump set to provide enormous pressure for pumping concrete.
[0004] Regarding relay pumping methods and devices, patent number CN111622779A, "A Pulse-type Pressure Compensation Long-Distance Concrete Conveying Device and its Usage Method," involves arranging several pneumatic booster pumps at intervals along the conveying pipeline. The air outlet pipes of the pneumatic booster pumps are connected to the conveying pipeline to compensate for the pushing pressure lost by the concrete during conveying, thereby maintaining a stable concrete pressure throughout the entire conveying pipeline and achieving long-distance concrete conveying.
[0005] Patent CN103541550A, entitled "A Construction Pumping System for Steel-Pipe Concrete in Super High-Rise Buildings," describes a system that connects a high-pressure pump to the discharge port and a low-pressure pump to a pouring hose, using a relay pump method to achieve the pumping purpose in super high-rise buildings. While existing technologies have solved some problems related to insufficient concrete pressure and relay pumping in high-rise construction...
[0006] Based on the above technical background, existing ultra-high pressure pumps still have the following problems: (1) Insufficient intelligence, unable to accurately control the pumping process; (2) Traditional pressure pumps have a lot of vibration and noise, which is not good for environmental protection. Summary of the Invention
[0007] This invention provides a circulating pulsed ultra-high concrete pumping device for bridge piers, aiming to provide a pumping device with high intelligence and precise control. This pumping device has low noise and powerful performance, making it suitable for widespread use in bridge engineering construction.
[0008] To achieve the above objectives, the technical solution of the present invention is as follows: A circulating pulsating concrete ultra-high-altitude pumping device for bridge piers includes a controller, a power pipe, an electric telescopic mechanism located within the power pipe, and a four-stage piston mechanism connected to the electric telescopic mechanism. The top of the power pipe is connected to a guide pipe via a reduced diameter connection, and one side of the guide pipe is connected to an output pipe for connection to the bottom end of an elevated concrete conveying pipeline. A side-standing U-shaped pipe is provided on one side of the power pipe, with a feeding mechanism connected to the middle section of the U-shaped pipe. The two ends of the U-shaped pipe are connected to the upper and lower parts of the power pipe, respectively. The four-piston mechanism includes a piston one located in the upper part of the power pipe, a piston two located in the lower part of the power pipe, a piston three located in the guide pipe, and a piston four located in the middle section of the U-shaped pipe. The electric telescopic mechanism is electrically connected to the controller via wires, and through the telescopic linkage of the four-stage piston mechanism, high-performance concrete is circulated and pulsated upwards along the elevated concrete conveying pipeline.
[0009] Preferably, the feeding mechanism includes a conical hopper and a chute connected to the bottom of the conical hopper and inclined to one side, wherein the end of the chute is sealed and fixedly connected to a pre-set discharge port in the middle of the U-shaped tube.
[0010] Preferably, the power pipe is arranged vertically, and a fixed plate is provided horizontally at the end of the power pipe away from the guide pipe. An electric telescopic mechanism is coaxially provided in the upper part of the power pipe. The fixed end of the electric telescopic mechanism is fixedly connected to the inner wall of the power pipe through a fixed block. The telescopic end is connected to a piston through a pressure sensor. The upper arm end of the U-shaped tube is sealed and fixedly connected to the feed port on the wall of the power pipe above the piston. The piston is slidably sealed to the inner wall of the power pipe. The pressure sensor and the electric telescopic mechanism are electrically connected to the controller through wires. The conical hopper is fixedly connected to the fixed plate through a bracket, and the U-shaped tube is fixedly connected to the fixed plate through a bracket.
[0011] Preferably, a force transmission rod is coaxially fixedly connected to the top of the piston one, the force transmission rod extends upward and is fixedly connected to the center position of the bottom of the piston three, the piston three is slidably sealed with the guide tube, when the piston one pushes the high-performance concrete upward and closes the inlet, the piston three opens the port of the output tube toward the guide tube side, the upper arm of the U-shaped tube is provided with a first electric shut-off valve, the output tube is provided with a second electric shut-off valve, and the first electric shut-off valve and the second electric shut-off valve are respectively electrically connected to the controller through wires.
[0012] Preferably, the lower end of the piston one is fixedly connected to several guide posts around an axis, the guide posts slidably penetrate the fixing block and extend downward, the bottom ends of the several guide posts are fixedly connected to the piston two, the piston two is slidably and sealed to the inner wall of the power pipe, and the piston two is drively connected to the piston four.
[0013] Preferably, the lower arm end of the U-shaped tube is sealed and fixedly connected to the vent port pre-installed on the lower outer wall of the power tube. The pistons two and four are connected by compressed air transmission. Specifically, an air inlet pipe is connected to the other side wall of the power tube opposite to the vent port. The air inlet pipe is connected to an electromagnetically controlled one-way valve one that restricts gas input into the power tube. An electromagnetically controlled one-way valve two that restricts gas input into the U-shaped tube is provided on the side of the lower arm of the U-shaped tube facing the vent port. An exhaust pipe is also connected to one side of the lower arm of the U-shaped tube, and an electromagnetically controlled one-way valve three is provided on the exhaust pipe. An air pressure sensor is also provided on the inner surface of the lower arm of the U-shaped tube. The electromagnetically controlled one-way valve one, electromagnetically controlled one-way valve two, electromagnetically controlled one-way valve three, and air pressure sensor are electrically connected to the controller via wires.
[0014] Preferably, the piston four is located in the middle section of the U-shaped tube and is slidably connected to the inner wall of the middle section of the U-shaped tube. The inner diameter one of the power tube is larger than the inner diameter two of the U-shaped tube. The ratio of the inner diameter one to the inner diameter two satisfies the following condition: when the piston two descends to a certain extent, the piston one descends synchronously, the feed port opens, and the pressurized air drives the piston four to move upward. At the same time as closing the discharge port, the high-performance concrete in the U-shaped tube is pushed into the upper part of the power tube. At this time, the piston three closes the port of the output tube facing the guide tube.
[0015] Preferably, the fixed plate is located at the bottom or top of the pumping device. When it is located at the top of the pumping device, a bottom plate is also provided on the side of the pumping device away from the fixed plate. The bottom plate and the fixed plate are fixedly connected by a support plate, and the conical hopper is fixedly connected to the bottom plate by a bracket.
[0016] Preferably, with the fixed plate located at the top of the pumping device, the transmission connection between piston two and piston four further includes a steel wire rope transmission connection. Specifically, the lower arm of the U-shaped tube is removed, and the middle section of the U-shaped tube extends upward from the upper arm and is fixedly connected to the fixed plate. A first steel wire rope through hole is provided on the fixed plate at a position opposite to the middle section of the U-shaped tube, and a second steel wire rope through hole is provided on the fixed plate at a position opposite to the end of the power pipe. A support roller is provided at the top of the fixed plate, and guide rollers are respectively provided on the side of the first and second steel wire rope through holes facing the support roller. One end of the steel wire rope is connected to the end of piston two, and the steel wire rope passes around the guide roller and the support roller, passes through the first steel wire rope through hole, and connects to the end of piston four. The transmission between piston two and piston four is achieved by the gravity of piston four itself, the extension force of the electric telescopic mechanism, the steel wire rope, the guide roller, and the support roller.
[0017] The piston one and piston four are respectively provided with sealing plates at their top ends to close the inlet or outlet. The piston four is also provided with a guide rod with a rectangular cross section at its end away from the sealing plate. A guide sleeve is also fixedly connected in the middle section of the U-shaped tube by a connecting rod. The guide rod is inserted into the guide sleeve and slides with the guide sleeve.
[0018] The end of piston two away from piston one and the end of piston four away from the sealing plate are respectively equipped with laser range sensors for real-time monitoring of the position of piston two or piston four. The laser range sensors are electrically connected to the controller.
[0019] Another objective of this invention is to provide a high-elevation concrete pumping construction system for bridge piers.
[0020] To achieve the above objectives, the technical solution adopted by this invention is as follows: A bridge pier concrete ultra-high pumping construction system includes the above-mentioned circulating pulsed bridge pier concrete ultra-high pumping device, and also includes a tower crane, a concrete mixer truck and an immersion vibrator for pump pipe installation.
[0021] Another objective of this invention is to provide a method for ultra-high pumping construction of concrete for bridge piers.
[0022] To achieve the above objectives, the technical solution adopted by this invention is as follows: A method for ultra-high concrete pumping construction of bridge piers, employing an ultra-high concrete pumping construction system for bridge piers, specifically includes the following steps: S1, Design the concrete mix proportion and determine the concrete pressure bleeding rate; Since the amount of water bleeding in concrete is inversely proportional to the fluidity of concrete, the pressure bleeding rate is a key control indicator for ultra-high pressure pumped concrete mixtures. The mix design should be based on the pressure bleeding rate of concrete as required by the specifications. S2, Detects concrete slump; Pumping tests were conducted using C50 concrete. The test results were statistically analyzed to determine the relationship between pumping height and concrete slump. Concrete with consistent fluidity was used. The test results were controlled by both concrete slump and spread. The average value of 10 tests was recorded. Analysis of pump loss data shows that as the pumping height increases, the loss of concrete fluidity does not show a linear relationship, but rather an increasing trend, leading to the conclusion that concrete pump loss is mainly affected by pressure. The higher the pumping height, the greater the pressure on the concrete, leading to an exponential increase in the loss of concrete fluidity. During construction, it is necessary to consider the normal loss of the delivery pipe length and the additional pressure loss due to the increased height. S3, Select the above-mentioned circulating pulsed bridge pier concrete ultra-high pumping device. S4, using concrete mixer trucks for concrete mixing; S5, the mixed concrete is poured through a circulating pulsed ultra-high concrete pumping device for bridge piers. S6, after the concrete is poured, curing work is carried out.
[0023] The present invention has the following beneficial effects: 1. This invention uses an electric telescopic mechanism to drive four pistons in a coordinated manner. Through the coordinated effect of the four pistons, it realizes the pulse-type pumping of high-performance concrete in a reciprocating manner, providing a new solution for high-altitude concrete delivery.
[0024] 2. The invention effectively enhances intelligence, enabling real-time monitoring and effective control of the entire device, timely detection of problems, and prevention of safety accidents during use.
[0025] 3. This invention can use a hydraulic cylinder or an electric cylinder as an electric telescopic mechanism, which can significantly reduce noise and avoid environmental noise pollution.
[0026] 4. This invention has multiple usage modes, such as the fixing plate being located at the bottom, the fixing plate being located at the top, pneumatic linkage, or wire rope linkage, which provides high flexibility in use. Attached Figure Description
[0027] Figure 1 A frontal sectional view of one embodiment of the present invention (corresponding to step 1 of embodiment 3). Figure 2 A frontal sectional view of one embodiment of the present invention (corresponding to step 2 of embodiment 3); Figure 3 A frontal sectional view of one embodiment of the present invention (corresponding to step 3 of embodiment 3); Figure 4 A cross-sectional structural schematic diagram of another embodiment of the present invention; Figure 5 A cross-sectional structural schematic diagram of an embodiment of the present invention using wire rope transmission; Figure 6 A schematic diagram showing the relationship between pumping pressure and pouring speed; Figure 7 This diagram illustrates the speed corresponding to different vertical heights when pouring under rated pressure.
[0028] In the diagram: 1. Fixed plate; 2. Conical hopper; 3. Support bracket 1; 4. Chute; 5. Piston 4; 6. Guide rod; 7. Limiting block; 8. Guide sleeve; 9. Connecting rod; 10. Upper part of power pipe; 101. Upper arm of U-shaped pipe; 102. Lower arm of U-shaped pipe; 103. First electric shut-off valve; 104. Second electric shut-off valve; 105. Inlet; 106. Outlet; 11. Lower part of power pipe; 12. Partition plate; 13. Electric telescopic mechanism; 14. Fixed block; 15. Guide column; 16. Piston 1; 17. Piston 2; 18. Inlet pipe; 19. Electromagnetic control check valve 2; 20. Exhaust pipe; 21. Support bracket 2; 22. Force transmission rod; 23. Guide pipe; 24. Piston 3; 25. Output pipe; 26. Sealing plate; 27. Base plate; 28. Support plate; 29. Support roller; 30. Guide roller; 31. First wire rope through hole; 32. Second wire rope through hole; 33. Wire rope.
[0029] It should be noted that the above figures are all schematic diagrams and the size ratios between the various structures of the present invention should not be understood based on the scale relationships shown in the figures. The actual size ratios should be set as needed. Detailed Implementation
[0030] The following description provides a detailed explanation of the embodiments of the present invention in a step-by-step manner. This description is only a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.
[0031] In the description of this invention, it should be noted that the terms "upper," "lower," "left," "right," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or a specific orientational structure and operation. Therefore, they should not be construed as limiting this invention.
[0032] Example 1: A circulating pulsed ultra-high concrete pumping device for bridge piers, such as... Figure 1-5 As shown, it includes a controller (not shown in the figure), a power pipe 10 / 11, an electric telescopic mechanism 13 located inside the power pipe, and a four-stage piston mechanism connected to the electric telescopic mechanism 13. The top end of the power pipe 10 / 11 is connected to a guide pipe 23 through a reduced diameter. One side of the guide pipe 23 is connected to an output pipe 25, which is used to connect to the bottom end of the high-altitude concrete conveying pipeline (not shown in the figure).
[0033] A U-shaped tube is provided on one side of the power pipe. The middle section of the U-shaped tube is connected to a feeding mechanism. The two ends of the U-shaped tube are respectively connected to the upper and lower parts of the power pipe. The four-piston mechanism includes a piston 16 located in the upper part of the power pipe, a piston 27 located in the lower part of the power pipe, a piston 3 24 located in the guide tube 23, and a piston 4 5 located in the middle section of the U-shaped tube. The electric telescopic mechanism 13 is electrically connected to the controller through a wire and realizes the upward transportation of high-performance concrete in a pulsating manner along the high-altitude concrete conveying pipeline through the telescopic linkage four-stage piston mechanism.
[0034] In this embodiment, the electric telescopic mechanism 13 can be selected from devices such as electric cylinders, hydraulic cylinders, or pneumatic cylinders that can be controlled by circuits for telescopic movement; the electric telescopic mechanism 13 is connected to a four-stage piston mechanism, which can realize cyclic pulse pumping of concrete; the pistons one to four involved in this invention are all equipped with sealing structures, which can refer to the sealing ring of engine pistons, the piston sealing design of cylinders or oil cylinders.
[0035] Example 2: like Figure 1 As shown, the feeding mechanism includes a conical hopper 2 and a chute 4 connected to the bottom of the conical hopper 2 and inclined to one side. The end of the chute 4 is sealed and fixedly connected to the discharge port preset in the middle of the U-shaped tube.
[0036] like Figure 1 As shown, the power pipe is arranged vertically, and a fixing plate 1 is provided horizontally at the end of the power pipe away from the guide pipe 23. An electric telescopic mechanism 13 is coaxially provided in the upper part of the power pipe. The fixed end of the electric telescopic mechanism 13 is fixedly connected to the inner wall of the power pipe through a fixing block 14. The telescopic end is connected to a piston 16 through a pressure sensor (not shown in the figure). The upper arm 101 end of the U-shaped pipe is sealed and fixedly connected to the feed port on the wall of the power pipe above the piston 16.
[0037] The piston 16 is slidably and sealed to the inner wall of the power pipe. The pressure sensor and the electric telescopic mechanism 13 are electrically connected to the controller via wires. The conical hopper 2 is fixedly connected to the fixed plate 1 via the bracket 3. The U-shaped tube is fixedly connected to the fixed plate 1 via the bracket 21.
[0038] like Figure 1 As shown, a force transmission rod 22 is coaxially fixedly connected to the top of piston 16. The force transmission rod 22 extends upward and is fixedly connected to the center of the bottom of piston 3 24. Piston 3 24 is slidably connected to guide tube 23. When piston 16 pushes high-performance concrete upward and closes the inlet, piston 3 24 opens the port of the output pipe facing the guide tube 23. The upper arm 101 of the U-shaped tube is equipped with a first electric shut-off valve 103, and the output pipe 25 is equipped with a second electric shut-off valve 104.
[0039] The first electric shut-off valve 103 and the second electric shut-off valve 104 are electrically connected to the controller via wires. When the output pipe is open, high-performance concrete can enter the output pipe through the power pipe. The electric telescopic mechanism operates cyclically, and the high-performance concrete can continuously enter the high-altitude concrete delivery pipeline under the push of the piston.
[0040] like Figure 1 As shown, the lower end of the piston 16 is fixedly connected to several guide posts 15 around the axis. The guide posts 15 slidably pass through the fixing block 14 and extend downward. The bottom ends of the several guide posts 15 are fixedly connected to the piston 2 17. The piston 2 17 is slidably connected to the inner wall of the power pipe and is connected to the piston 4 5 in a transmission manner.
[0041] In this embodiment, when piston one is raised and lowered by the electric telescopic mechanism, piston one, piston two, piston three and piston four move synchronously. This synergistic effect realizes the cyclic pulse pumping of high-performance concrete slurry.
[0042] Example 3: Based on Example 2, such as Figure 1-3 As shown, the lower arm 102 of the U-shaped tube is sealed and fixedly connected to the vent port pre-installed on the lower outer wall of the power tube, and the piston 2 17 and piston 4 5 are connected by compressed air transmission.
[0043] Specifically: an air inlet pipe 18 is connected to the other side wall of the power pipe opposite to the vent. The air inlet pipe 18 is connected to an electromagnetically controlled one-way valve (not marked in the figure) that restricts the input of gas into the power pipe. An electromagnetically controlled one-way valve 19 that restricts the input of gas into the U-shaped pipe is provided on the side of the lower arm 102 of the U-shaped pipe facing the vent. An exhaust pipe 20 is also connected to one side of the lower arm 102 of the U-shaped pipe. An electromagnetically controlled one-way valve 3 (not marked in the figure) is provided on the exhaust pipe 20. An air pressure sensor (not shown in the figure) is also provided on the inner surface of the lower arm 102 of the U-shaped pipe. The electromagnetically controlled one-way valve 1, electromagnetically controlled one-way valve 29, electromagnetically controlled one-way valve 3, and air pressure sensor are electrically connected to the controller through wires.
[0044] like Figure 1-3 As shown, piston 4 5 is located in the middle section of the U-shaped tube and is slidably connected to the inner wall of the middle section of the U-shaped tube. The inner diameter of the power tube is larger than the inner diameter of the U-shaped tube. The ratio of inner diameter 1 to inner diameter 2 satisfies the following condition: when piston 2 17 descends to a certain extent, piston 1 16 descends synchronously, the feed port opens, and the pressurized air drives piston 4 5 to move upward. At the same time as closing the discharge port, the high-performance concrete in the U-shaped tube is pushed into the upper part 10 of the power tube. At this time, piston 3 24 closes the port of the output pipe 25 facing the guide pipe 23.
[0045] In this embodiment, the process of driving four pistons through an electric telescopic mechanism to achieve cyclic pulse pumping is as follows: Step 1, as follows Figure 1 As shown, in the initial state, piston 4 5 closes the discharge port, and at the same time, piston 3 24 closes the port of output pipe 25 facing the guide pipe 23; piston 1 is located below the feed port, and the feed port is open; piston 2 is located on the side of the lower part 11 of the power pipe near the upper edge of the air intake pipe 18, and is in the state of compressing air. The electromagnetic control check valve 2 19 is closed, locking the position of piston 4. Step 2, as follows Figure 2 As shown, when piston 16 moves upward and closes the inlet through sealing plate 26 (described below), electromagnetic control check valve 3 on exhaust pipe 20 opens. After exhaust, piston 4 5 falls back and is blocked by limit block on the inner wall of the middle section of U-shaped tube. At this time, the outlet opens, and high-performance concrete slurry flows into the middle section of U-shaped tube due to gravity (in actual use, the conical hopper should be higher than the upper arm 101 of U-shaped tube to ensure that the slurry can smoothly enter the middle section of U-shaped tube), realizing U-shaped tube replenishment; at the same time, the air pressure sensor detects that the pressure has reached the set threshold, that is, the threshold for piston 4 to fall back to the position, and closes electromagnetic control check valve 3; during this process, piston 2 moves upward synchronously with piston 1, electromagnetic control check valve 1 on air inlet pipe 18 opens, and air enters the lower part 11 of power pipe and the pipe body located below piston 2; Step 3, as follows Figure 3 As shown, piston one continues to move upward, continuing to push the high-performance concrete upward while keeping the feed inlet closed, and the high-performance concrete is in a continuous output state. The lower part 11 of the power pipe and the pipe body located below piston two continuously intake air. Step 4: After piston one reaches its upper limit, it begins to fall back. At this time, electromagnetic control check valve one on the air inlet pipe 18 closes and electromagnetic control check valve two 19 opens. The gas begins to gradually compress into the U-shaped tube. The compressed air pushes piston four upward. After the outlet is sealed by the sealing plate above piston four, piston four continues to rise, thereby pushing the slurry in the U-shaped tube into the upper part of the power pipe. Step 5: After piston four returns to the initial state of step 1, repeat steps 1-4 in a cyclical manner to achieve cyclic pulse pumping of slurry.
[0046] Example 4: Based on Example 3, such as Figure 1-4 As shown, the fixing plate 1 is located at the bottom of the pumping device. Figure 1-3 (with a fixed plate as the base) or located on top of the pumping device ( Figure 5When the hopper is located at the top of the pumping device, the pumping device is also provided with a bottom plate 27 on the side away from the fixed plate 1. The bottom plate 27 is fixedly connected to the fixed plate 1 through a support plate 28. The conical hopper 2 is fixedly connected to the bottom plate 27 through a bracket 3, that is, indirectly fixedly connected to the fixed plate 1.
[0047] like Figure 1-3 As shown, due to the gravity of the slurry itself, long-term use will have a certain impact on the sealing mechanism of the piston. However, when the fixing plate is placed at the top, the gravity factor is overcome. Instead, the gravity of the slurry itself will cause the fine sand particles to flow away from the piston, thereby extending the service life of the device.
[0048] Example 5: Based on Example 2, such as Figure 5 As shown, with the fixed plate 1 located at the top of the pumping device, the transmission connection between the piston 2 17 and the piston 4 5 also includes a transmission connection via a steel wire rope. Specifically, the lower arm 102 of the U-shaped tube is removed, and the middle section of the U-shaped tube extends upward from the upper arm 101 away from the U-shaped tube and is fixedly connected to the fixed plate 1.
[0049] A first wire rope through hole 31 is provided on the fixed plate 1 at a position opposite to the middle section of the U-shaped tube, and a second wire rope through hole 32 is provided on the fixed plate 1 at a position opposite to the end of the power pipe. A support roller 29 is provided at the top of the fixed plate 1, and guide rollers 30 are respectively provided on the side of the first wire rope through hole 31 and the second wire rope through hole 32 facing the support roller. One end of the wire rope 33 is connected to the end of the second piston 17. The wire rope 33 passes around the guide roller 30 and the support roller 29 and then passes through the first wire rope through hole 31 to connect to the end of the fourth piston 5. The transmission of the second piston 17 and the fourth piston 14 is realized by the gravity of the fourth piston 5, the extension force of the electric telescopic mechanism 13, the wire rope 33, the guide roller 30, and the support roller 29.
[0050] In this embodiment, as Figure 5 As shown, the process of achieving cyclic pulse pumping by driving four pistons through an electric telescopic mechanism is as follows: When piston one moves downward, the feed inlet 105 is simultaneously closed. Piston two moves synchronously with piston one, driving piston four 5 upward via a steel wire rope. The discharge outlet 106 opens, and while high-performance concrete is output through piston one, slurry is replenished into the U-shaped pipe below piston four through discharge outlet 106. After piston one reaches its downward limit, it moves upward, and piston two follows. Under the gravity of piston four, the slurry in the U-shaped pipe is forced into the power pipe. At the same time, piston three closes the output pipe. Then, piston one moves downward again, and this cycle repeats to achieve continuous output of high-performance concrete in a cyclic pulse manner.
[0051] In this embodiment, the length of each piston is set as needed, with the aim of ensuring coordinated operation between the pistons and guaranteeing the normal operation of slurry supply and output. The wire rope drive can also be replaced with a chain drive, while maintaining the same principle.
[0052] Example 6 like Figure 1 As shown, the top of piston 16 and piston 4 5 are respectively provided with sealing plates 26 for closing the feed port 105 or the discharge port 106. The end of piston 4 5 away from the sealing plate 26 is also provided with a guide rod 6 with a rectangular cross section. In the middle section of the U-shaped tube, a guide sleeve 8 is fixedly connected by a connecting rod 9. The guide rod 6 is inserted into the guide sleeve 8 and slides with the guide sleeve 8.
[0053] In this embodiment, the rectangular cross-section guide rod and the guide sleeve work together to guide the piston and prevent the sealing plate from rotating.
[0054] Example 7 like Figure 1 As shown, the end of piston 2 17 furthest from piston 1 16 and the end of piston 4 5 furthest from sealing plate 26 are respectively equipped with laser range sensors (not marked in the figure) for real-time monitoring of the position of piston 2 17 or piston 4 5. The laser range sensors are electrically connected to the controller. The principle of the laser range sensors monitoring the position of piston 2 and piston 4 is as follows: the laser measuring beam is projected onto a preset position at the lower end of the power tube or the lower middle section of the U-shaped tube, and the position of piston 2 or piston 4 is determined based on the measured distance value.
[0055] In this embodiment, the laser rangefinder is used to monitor the real-time position of piston two and piston four, thereby effectively monitoring the position of the four pistons of the present invention. Once an abnormal position occurs, the controller can shut down the relevant pipelines through the first electric shut-off valve and the second electric shut-off valve, and stop the machine and alarm.
[0056] At the same time, it is understandable that when the air pressure sensor displays an abnormal value, the controller will also shut down the relevant pipelines and issue a shutdown alarm, indicating that the piston sealing mechanism may have been damaged.
[0057] In addition, when the pressure sensor detects data exceeding the threshold, the controller will also shut down the relevant pipelines and trigger an alarm, allowing maintenance personnel to check for related problems and perform repairs if necessary.
[0058] Through the above settings, the intelligence of the present invention is effectively enhanced, enabling real-time monitoring and effective control of the entire device, timely detection of problems, and prevention of safety accidents during use.
[0059] Example 8 A bridge pier concrete ultra-high pumping construction system includes the above-mentioned circulating pulsed bridge pier concrete ultra-high pumping device, and also includes a tower crane, a concrete mixer truck and an immersion vibrator for pump pipe installation.
[0060] A method for ultra-high concrete pumping construction of bridge piers, employing an ultra-high concrete pumping construction system for bridge piers, specifically includes the following steps: S1, Design the concrete mix proportion and determine the concrete pressure bleeding rate; Since the amount of water bleeding in concrete is inversely proportional to the fluidity of concrete, the pressure bleeding rate is a key control indicator for ultra-high pressure pumped concrete mixtures. The mix design should be based on the pressure bleeding rate of concrete as required by the specifications. S2, Detects concrete slump; Pumping tests were conducted using C50 concrete. The test results were statistically analyzed to determine the relationship between pumping height and concrete slump. Concrete with consistent fluidity was used. The test results were controlled by both concrete slump and spread. The average value of 10 tests was recorded. Analysis of pump loss data shows that as the pumping height increases, the loss of concrete fluidity does not show a linear relationship, but rather an increasing trend, leading to the conclusion that concrete pump loss is mainly affected by pressure. The higher the pumping height, the greater the pressure on the concrete, leading to an exponential increase in the loss of concrete fluidity. During construction, it is necessary to consider the normal loss of the delivery pipe length and the additional pressure loss due to the increased height. S3, Select the above-mentioned circulating pulsed ultra-high concrete pumping device for bridge piers; S4, Use a concrete mixer truck to mix the concrete; S5, The mixed concrete is poured through the circulating pulsed ultra-high concrete pumping device for bridge piers; S6, Curing work is carried out after the concrete is poured.
[0061] Example 9 For a certain construction project: The bridge is a key control project under construction. It is a 125m + 240m + 125m double-tower, double-cable-stayed, semi-floating steel-concrete composite beam cable-stayed bridge. The towers are made of reinforced concrete with a concrete grade of C50. Tower #4 is 190.314m high, with an upper tower column of 74m and a lower tower column of 116.314m. Tower #5 is 183.374m high, with an upper tower column of 74m and a lower tower column of 109.374m.
[0062] The construction work includes the following: 1. Optimize the mix ratio to ensure smooth pouring.
[0063] For ultra-high pumping, the concrete mix design was optimized to ensure that the various properties of the concrete meet the needs of on-site construction; the controlled variable method was used to verify the relationship between concrete performance and pump loss, ensuring smooth pouring.
[0064] (1) Concrete pressure bleeding rate: Since the amount of concrete bleeding is inversely proportional to the fluidity of concrete, the pressure bleeding rate is a key control indicator for ultra-high pumped concrete mixtures. The concrete pressure bleeding rate is required by the specification as shown in the table below. When designing the mix proportion, the concrete pressure bleeding rate should be strictly controlled, and the concrete pressure bleeding rate should be minimized as much as possible while meeting the requirements of the specification.
[0065] Table 5.2-1 Requirements for concrete pressure bleeding rate at different pumping heights (2) Concrete slump: C50 concrete was used for pumping tests. The test results were statistically analyzed to determine the relationship between pumping height and concrete slump loss. Concrete with consistent fluidity was used, and the test results were controlled by both concrete slump and spread. The average value of 10 tests was recorded. Through pump loss data analysis, it was found that as the pumping height increased, the loss of concrete fluidity did not show a linear relationship, but rather an increasing trend. It was concluded that concrete pump loss is mainly affected by pressure. The higher the pumping height, the greater the pressure on the concrete, leading to an exponential increase in concrete fluidity loss. During construction, the normal delivery pipe length loss and the additional pressure height loss need to be considered based on the increase in height.
[0066] Table 5.2-2 C50 Concrete Mix Proportion Table 5.2-3 Relationship between concrete fluidity loss and pumping height Based on the principles of pump loss loss, concrete bubble breakage ball effect, and increased water absorption under aggregate pressure, the principle is that the larger the amount of air bubbles in the concrete, the more abundant the paste, and the smaller the proportion of loss reduction. The higher the initial concrete fluidity, the smaller the concrete loss. Experiments were conducted according to the mix proportions in the table above to verify the fluidity loss of concretes with different fluidities at the same pumping height.
[0067] II. Selection of pumping equipment.
[0068] (1) Theoretical working pressure of concrete pump: The above formula is for calculating different types of pressure loss during concrete pumping, where: P – Concrete delivery; P1—The pressure loss along the flow path of concrete within the pump pipe; P2—Local pressure loss caused by bends, tapered pipes, and flexible hoses installed in concrete piping; P3 – Pressure generated by the weight of concrete during vertical pumping.
[0069] The industry standard JGJ / T 10-2011 "Technical Specification for Concrete Pumping Construction" recommends a calculation formula for P1, namely: ; In the formula, △PH is the pressure loss per meter of horizontal pipe (Pa / m); r is the radius of the conveying pipe (m); K1 is the adhesion coefficient (Pa); K1=300-S1; K2 is the velocity coefficient (Pa / m / s); K2=400-S1; S1—Concrete slump (mm); — The ratio of the valve switching time to the piston pressing time is generally 0.30; P2 gives the equivalent horizontal resistance conversion length of the conveying pipe fitting in the standard.
[0070] Equivalent horizontal resistance conversion method for pipeline fittings: Table 5.3-1 Equivalent Horizontal Resistance Conversion for Pipeline Fittings In the formula, ρ—concrete density 2400 (kg / m3); g—acceleration due to gravity (m / s²). 2 H—Pumping height (m).
[0071] Table 5.3-2 Construction Configuration Table From Table 5.3-2, the distance between vertical pipes and horizontal pipes is converted using a conversion factor of 4. For a 90° bend with a diameter of 1000mm, each resistance is converted to a horizontal resistance length of 9m. For a tapered pipe, each length is 8m, and for a rubber hose, each length is 20m.
[0072] P1=0.008×(50+200×4)+1.2=8.0MPa; P2=0.008×(8×9+8+20)=0.8MPa; P3 =2.456×9.8×200 / 1000=4.8MPa; P=P1+P2+P3=8+0.8+4.8=13.6MPa; According to theoretical calculation formulas, the faster the concrete pouring speed, the greater the pressure loss per meter, and the higher the required theoretical maximum output pressure. Table 5.3-2 shows the theoretical pressure under the same pouring condition at different pouring speeds. Figure 6 With the same theoretical output pressure of 13.6 MPa, concrete is pumped at different vertical heights according to the operating conditions in Table 5.3-2. The higher the vertical height, the slower the concrete pouring speed. The theoretical pouring conditions are as follows: Figure 7Therefore, the concrete pumping distance can be calculated based on the concrete pouring speed according to the construction conditions. If the calculated pouring speed is less than the actual pouring speed, the theoretical output pressure of the selected equipment will be low, resulting in slow on-site construction. The extended interval between the upper and lower layers of pouring will easily cause cold joints, affecting the construction quality.
[0073] Concrete pump working efficiency: Many factors affect the actual working efficiency of concrete pumps. Air and grout leakage at pump pipe joints, unstable pump pipes that sway up and down and consume kinetic energy, and poor coaxiality of the delivery pipes can all reduce working efficiency.
[0074] Table 5.3-3 Concrete Pump Working Efficiency Table As the total pressure loss during construction increases, the working efficiency of concrete pumps gradually decreases. Under normal operating conditions, the working efficiency of concrete pumps is between 60% and 80%.
[0075] Selection of concrete delivery pipes: The strength of concrete pump pipes should be adapted to the pumping conditions and be able to withstand the conveying pressure of the concrete pump. Concrete pump pipes should not have defects such as cracks, holes, dents, and bends, and there should be no residue or debris inside the pipes. When the maximum vertical pumping height is greater than 150m, high-pressure wear-resistant pump pipes should be selected for concrete pumps. When new and old pipes are used together, the new pipe should be placed in the location with higher pumping pressure. It is advisable to set up a spare pump pipe. The minimum inner diameter of the pump pipe should meet the requirements in the table below.
[0076] Table 5.3-4 Minimum Inner Diameter of Delivery Pipe Selection of concrete conveying pipe fittings: When the vertical height exceeds 100 meters, a shut-off valve should be installed at the pump outlet, 1-2 sections of the conveying pipe, to prevent concrete backflow under special circumstances. When piping vertically upwards, the potential energy of the concrete increases with height, and there is a tendency for concrete to backflow. Therefore, a certain length of horizontal pipe should be laid directly between the concrete pump and the vertical piping. The ratio of the horizontal to vertical length of the conveying pipe should preferably be 1:5 to ensure sufficient resistance to prevent concrete backflow.
[0077] Installation of concrete conveying pipe fittings: Ensure the conveying pipe joints are well sealed. Leakage at the joints affects the workability of the concrete. Under pressure, cement slurry will be discharged, reducing the amount of concrete slurry, altering the mix proportions, decreasing fluidity, and affecting pumping performance. During pouring, check the sidewalls of the conveying pipe for signs of slurry seepage and wetting; if seepage is observed, tighten the fittings immediately.
[0078] III. Maintenance Points (1) Control of maintenance time for different parts.
[0079] Ultra-high-efficiency pumped concrete is highly fluid with a large volume of concrete paste. If curing is not timely, moisture loss is very likely, leading to a significant reduction in concrete strength. The top surface concrete is roughened and immediately placed in water for curing. Other parts of the concrete are cured with the formwork in place. After the formwork is removed once the required strength is reached, curing operations are completed within 2 hours, ensuring no areas are missed during spraying or coating, and guaranteeing continuous moisture retention for the concrete.
[0080] (2) Selection of maintenance methods.
[0081] Ultra-high-speed pumped concrete often employs climbing formwork construction, where the operating platform moves upwards with each construction segment. During fast-paced construction, the next segment (with a strength greater than 15 MPa) needs to be constructed using climbing formwork just 5 days after the previous segment is poured. Ordinary Portland cement requires a curing period of at least 7 days, and the curing time for vertical structural concrete should be appropriately extended. Simply using water spraying for curing cannot meet the required curing period. Two methods can be used: a combination of water spraying followed by applying a curing agent, or using a curing agent alone. Water spraying for curing is prohibited during winter construction when the average daily temperature is below 5°C.
[0082] IV. Key Control Points During Construction (1) Inspection of equipment and fittings.
[0083] The rubber hose at the head of the delivery pipe should be inspected and replaced regularly. With wear and tear, the steel wires inside the hose may become exposed. When multiple exposed steel wires are combined, they will become tangled and clogged when concrete passes through. Increased pump pressure will also increase the pressure on the delivery pipe, which may even cause the rubber hose to burst, affecting construction safety.
[0084] (2) The concrete is discharged evenly.
[0085] Before unloading, the concrete mixer truck should be quickly reversed to thoroughly mix the concrete. Ultra-high-speed pumped concrete has high fluidity, and the slurry and aggregates are easily separated. During transportation and waiting, stones are prone to sedimentation. Rapid mixing ensures the homogeneity of the concrete and improves pumpability. When the concrete mixer truck is unloaded to one-third capacity, the concrete in the tank needs to be mixed again to ensure thorough mixing.
[0086] The concrete moves along the spiral direction of the helical blades. During discharge, the mixing drum is rotated, and the concrete is discharged outward along the blades. The helical blades have a certain height. During normal discharge, the slurry is at the top of the concrete and flows out first. Therefore, when the discharge reaches this position, the concrete needs to be mixed again to ensure uniformity.
[0087] (3) Measures to control the intermittent pouring.
[0088] If there are interruptions during pouring, ensure that the concrete level in the pump truck hopper is less than one-third of the total capacity before each interruption. More material left in the hopper will cause more aggregate to settle during mixing, potentially leading to pump blockage upon restarting. For longer interruptions, perform two reverse pumping strokes followed by two forward pumping strokes every 5 minutes. Because ultra-high-velocity concrete pumping results in high concrete pressure due to gravity, gas and low-density free water rise under this pressure, increasing the cohesiveness, density, and unit weight of the concrete in certain areas. This increases friction with the pipe wall, making it prone to blockage at bends during subsequent pumping. Therefore, reverse and forward pumping are necessary to move the concrete within the pipe wall and prevent it from sticking to it.
[0089] (4) Operation of the cloth feeder.
[0090] Pumping should be stopped when the concrete placing boom changes angle, and large-angle changes in the discharge direction are strictly prohibited during pouring. In particular, when the discharge port changes from 90° to 180° with the horizontal conveying pipe, the change should be made slowly; otherwise, the change in the direction of concrete stress will cause a sudden increase in conveying pressure and damage the pump.
[0091] This embodiment is intended to describe the invention and simplify the description, and is not intended to indicate or imply that the device or element referred to must have a specific orientation, or a specific orientation construction and operation, and therefore should not be construed as a limitation of the invention.
Claims
1. A circulating pulsed ultra-high concrete pumping device for bridge piers, characterized in that, It includes a controller, a power pipe, an electric telescopic mechanism located inside the power pipe, and a four-stage piston mechanism connected to the electric telescopic mechanism. The top of the power pipe is connected to a guide pipe through a reduced diameter, and one side of the guide pipe is connected to an output pipe. The output pipe is used to connect to the bottom end of the high-altitude concrete conveying pipeline. The power pipe has a side-standing U-shaped pipe on one side, the middle section of the U-shaped pipe is connected to a feeding mechanism, and the two ends of the U-shaped pipe are respectively connected to the upper and lower parts of the power pipe. The four-piston mechanism includes a piston 1 located in the upper part of the power tube, a piston 2 located in the lower part of the power tube, a piston 3 located in the guide tube, and a piston 4 located in the middle section of the U-shaped tube. The electric telescopic mechanism is electrically connected to the controller via a wire, and through a telescopic linkage four-stage piston mechanism, it realizes the upward cyclical transport of high-performance concrete along the high-altitude concrete conveying pipeline.
2. The circulating pulsed ultra-high concrete pumping device for bridge piers as described in claim 1, characterized in that, The feeding mechanism includes a conical hopper and a chute connected to the bottom of the conical hopper and inclined to one side. The end of the chute is sealed and fixedly connected to the discharge port preset in the middle of the U-shaped tube. The power pipe is arranged vertically, and a fixed plate is provided horizontally at the end of the power pipe away from the guide pipe. An electric telescopic mechanism is coaxially provided in the upper part of the power pipe. The fixed end of the electric telescopic mechanism is fixedly connected to the inner wall of the power pipe through a fixed block, and the telescopic end is connected to a piston through a pressure sensor. The upper arm end of the U-shaped tube is sealed and fixedly connected to the feed port on the wall of the power pipe above the piston. The piston is sealed and slidably connected to the inner wall of the power pipe. The pressure sensor and the electric telescopic mechanism are electrically connected to the controller through wires. The conical hopper is fixedly connected to the fixed plate through the bracket, and the U-shaped tube is fixedly connected to the fixed plate through the bracket.
3. The circulating pulsed ultra-high concrete pumping device for bridge piers as described in claim 2, characterized in that, A force transmission rod is coaxially and fixedly connected to the top of the piston, and the force transmission rod extends upward and is fixedly connected to the center of the bottom of the piston. The piston three is slidably connected to the guide tube in a sealed manner. When the piston one pushes the high-performance concrete upward and closes the inlet, the piston three opens the outlet pipe to the side of the guide tube. The upper arm of the U-shaped tube is equipped with a first electric shut-off valve, and the outlet pipe is equipped with a second electric shut-off valve. The first electric shut-off valve and the second electric shut-off valve are electrically connected to the controller through wires.
4. The circulating pulsed ultra-high concrete pumping device for bridge piers as described in claim 3, characterized in that, The lower end of piston one is fixedly connected to several guide posts around an axis. The guide posts can slide through the fixed block and extend downward. The bottom ends of the several guide posts are fixedly connected to piston two. Piston two is slidably connected to the inner wall of the power tube and is drivenly connected to piston four.
5. The circulating pulsed ultra-high concrete pumping device for bridge piers as described in claim 4, characterized in that, The lower arm end of the U-shaped tube is sealed and fixedly connected to the vent port pre-set on the lower outer wall of the power tube. The piston two and piston four are connected by compressed air transmission. Specifically, an air inlet pipe is connected to the other side wall of the power tube opposite to the vent port. The intake pipe is connected to an electromagnetically controlled one-way valve 1 that restricts the input of gas into the power pipe. The lower arm of the U-shaped pipe is provided with an electromagnetically controlled one-way valve 2 that restricts the input of gas into the U-shaped pipe on the side facing the air inlet. An exhaust pipe is also connected to one side of the lower arm of the U-shaped pipe, and an electromagnetically controlled one-way valve 3 is provided on the exhaust pipe. An air pressure sensor is also provided on the inner surface of the lower arm of the U-shaped tube. The electromagnetic control check valve one, electromagnetic control check valve two, electromagnetic control check valve three, and air pressure sensor are electrically connected to the controller through wires.
6. The circulating pulsed ultra-high concrete pumping device for bridge piers as described in claim 5, characterized in that, The piston is located in the middle section of the U-shaped tube and is slidably and sealingly connected to the inner wall of the middle section of the U-shaped tube. The inner diameter of the power pipe is greater than the inner diameter of the U-shaped pipe. The ratio of the inner diameter of the power pipe to the inner diameter of the U-shaped pipe satisfies the following condition: when the piston 2 descends to a certain extent, the piston 1 descends synchronously, the feed port opens, and the pressurized air drives the piston 4 to move upward. At the same time as closing the discharge port, the high-performance concrete in the U-shaped pipe is pushed into the upper part of the power pipe. At this time, the piston 3 closes the port of the output pipe facing the guide pipe.
7. The circulating pulsed ultra-high concrete pumping device for bridge piers as described in claim 4, characterized in that, The fixed plate is located at the bottom or top of the pumping device. When it is located at the top of the pumping device, a bottom plate is also provided on the side of the pumping device away from the fixed plate. The bottom plate and the fixed plate are fixedly connected by a support plate. The conical hopper is fixedly connected to the bottom plate by a bracket.
8. The circulating pulsed ultra-high concrete pumping device for bridge piers as described in claim 7, characterized in that, With the fixed plate located at the top of the pumping device, the transmission connection between piston two and piston four also includes a transmission connection via steel wire rope. Specifically, the lower arm of the U-shaped tube is removed, and the middle section of the U-shaped tube extends upward from the upper arm of the U-shaped tube and is fixedly connected to the fixed plate. A first steel wire rope through hole is provided on the fixed plate at a position opposite to the middle section of the U-shaped tube, and a second steel wire rope through hole is provided on the fixed plate at a position opposite to the end of the power pipe. The fixed plate is provided with a support roller at the top and guide rollers are provided on the side of the first and second wire rope through holes facing the support rollers. One end of the wire rope is connected to the two ends of the piston. After passing around the guide roller and the support roller, the wire rope passes through the first wire rope through hole and connects to the end of the piston. The transmission between the piston and the piston is realized by the weight of the piston itself, the extension force of the electric telescopic mechanism, the wire rope, the guide roller and the support roller. The piston one and piston four are respectively provided with sealing plates at the top end to close the inlet or outlet. The piston four is also provided with a guide rod with a rectangular cross section at the end away from the sealing plate. A guide sleeve is also fixedly connected in the middle section of the U-shaped tube by a connecting rod. The guide rod is inserted into the guide sleeve and slides with the guide sleeve. The end of piston two away from piston one and the end of piston four away from the sealing plate are respectively equipped with laser range sensors for real-time monitoring of the position of piston two or piston four. The laser range sensors are electrically connected to the controller.
9. A system for pumping ultra-high concrete for bridge piers, characterized in that, The device includes a circulating pulsating concrete ultra-high pumping device for bridge piers as described in claim 8, and also includes a tower crane, a concrete mixer truck, and an immersion vibrator for pump pipe installation.
10. A method for ultra-high concrete pumping construction of bridge piers, characterized in that, The bridge pier concrete ultra-high pumping construction system described in claim 9 specifically includes the following steps: S1, Design the concrete mix proportion and determine the concrete pressure bleeding rate; Since the amount of water bleeding in concrete is inversely proportional to the fluidity of concrete, the pressure bleeding rate is a key control indicator for ultra-high pressure pumped concrete mixtures. The mix design should be based on the pressure bleeding rate of concrete as required by the specifications. S2, Detects concrete slump; Pumping tests were conducted using C50 concrete. The test results were statistically analyzed to determine the relationship between pumping height and concrete slump. Concrete with consistent fluidity was used. The test results were controlled by both concrete slump and spread. The average value of 10 tests was recorded. Analysis of pump loss data shows that as the pumping height increases, the loss of concrete fluidity does not exhibit a linear relationship, but rather an increasing trend, leading to the conclusion that concrete pump loss is mainly affected by pressure. The higher the pumping height, the greater the pressure on the concrete, leading to an exponential increase in the loss of concrete fluidity. During construction, it is necessary to consider the normal loss of the delivery pipe length and the additional pressure loss due to the increased height. S3, Select the above-mentioned circulating pulsed bridge pier concrete ultra-high pumping device. S4, using concrete mixer trucks for concrete mixing; S5, the mixed concrete is poured through a circulating pulsed ultra-high concrete pumping device for bridge piers. S6, after the concrete is poured, curing work is carried out.
Citation Information
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