Synchronous tensioning system for prestressed carbon plates of combined box girder of bridge

Abstract

The utility model discloses a bridge combined box girder prestress carbon plate synchronous tensioning system which comprises a control mainframe box, an electromagnetic valve set, a servo hydraulic pump station and a working part. Wherein the working part comprises a high-pressure oil cylinder, a tensioning end tool, a fixed end tool and a steel cable, the two ends of the steel cable are connected with the tensioning end tool and the fixed end tool respectively, the high-pressure oil cylinder is installed on the side portion of the tensioning end tool, and a displacement sensor is arranged on the side wall of the high-pressure oil cylinder; a hydraulic pump station signal connector, an electromagnetic valve group signal connector and a displacement signal connector are arranged in the control mainframe box; the control mainframe box is in signal connection with the electromagnetic valve set, the servo hydraulic pump station and the working part through an electromagnetic valve set signal connector, a hydraulic pump station signal connector and a displacement signal connector. The electromagnetic valve group is in signal connection with the servo hydraulic pump station and then is respectively connected with the working part; and the comprehensive benefit and the economic benefit are greatly improved.

Description

TECHNICAL FIELD

[0001] The utility model belongs to bridge reinforcing technical field, more specifically, the utility model relates to a bridge combined box girder prestressed carbon plate synchronous tension system. BACKGROUND

[0002] Prestressed CFRP (carbon fiber reinforced composite material) is widely used in the current bridge preventive maintenance and bridge reinforcement. Carbon plate has good mechanical properties and aging resistance, compared with other reinforcement methods, prestressed carbon plate tension has obvious advantages in economy, practicality and other dimensions. After more than 10 years of development, this technology has matured from materials to construction, and has become one of the important technologies for bridge preventive maintenance and reinforcement construction.

[0003] In the construction process monitoring and tracking evaluation of the reinforcement effect after construction in recent years, the reinforcement effect of individual projects deviates from the design expectation, and the occasional construction quality or tension stress cannot meet the expected requirements. It can be seen that the construction quality of prestressed carbon plate tension is easily affected by construction tools, operation ability and professional degree of construction workers and other factors.

[0004] At present, the prestressed carbon plate tension construction in the whole country basically adopts hand pressure pump combined with jack for tension operation. The oil pressure stability of hand pressure pump is not strong, and several hundred times of repeated pressure operation is needed for single carbon plate tension. It is difficult for construction workers to realize uniform speed operation, and often multiple people alternate construction, often resulting in inaccurate reading and many other problems, which brings certain uncertainty factors to construction quality control. Secondly, single carbon plate needs to be pre-tensioned and formally tensioned twice according to the standard construction process, and a group of skilled workers needs about 1.5 hours to construct a carbon plate, and the work efficiency still has a large space for improvement. SUMMARY

[0005] In order to solve the above technical problems, the utility model provides a bridge combined box girder prestressed carbon plate synchronous tension system.

[0006] In order to realize the above purpose, the utility model takes the technical scheme that a bridge combined box girder prestressed carbon plate synchronous tension system, including control host box, electromagnetic valve group, servo hydraulic pump station and working part, wherein:

[0007] The working part includes high-pressure oil cylinder, tension end tooling, fixed end tooling and steel cable, the two ends of the steel cable are connected with the tension end tooling and the fixed end tooling respectively, the high-pressure oil cylinder is installed on the side of the tension end tooling, and the side wall of the high-pressure oil cylinder is provided with a displacement sensor;

[0008] The control host box is internally provided with a hydraulic pump station signal connector, an electromagnetic valve group signal connector and a displacement signal connector; the control host box is internally connected with the electromagnetic valve group, the servo hydraulic pump station and the working part through the electromagnetic valve group signal connector, the hydraulic pump station signal connector and the displacement signal connector.

[0009] The electromagnetic valve group and the servo hydraulic pump station are connected with the working part through the signal connection.

[0010] The utility model discloses a kind of bridge combined box girder prestressed carbon plate synchronous tensioning systems, oil cylinder backflow separation valve is equipped on the loop of servo hydraulic pump station.

[0011] The utility model discloses a kind of bridge combined box girder prestressed carbon plate synchronous tensioning systems, and the working part can be provided with multiple and be arranged in parallel on system.

[0012] The utility model discloses a kind of bridge combined box girder prestressed carbon plate synchronous tensioning systems, steel cable surface is covered with pressing plate.

[0013] The utility model discloses a kind of bridge combined box girder prestressed carbon plate synchronous tensioning systems, the electromagnetic valve group includes oil pipe joint, electromagnetic reversing valve, valve group signal connector and pressure sensor, electromagnetic valve group is connected with servo hydraulic pump station through oil pipe joint, electromagnetic valve group valve group signal connector is connected with control host box, high pressure oil cylinder of electromagnetic valve group and working part are connected through pipeline, and pressure sensor is arranged on pipeline and monitors oil pressure.

[0014] Compared with the prior art, the utility model has the following beneficial effects: 1. Work efficiency and safety results: the multiple beams or multiple carbon plates in a span are synchronously pre-tensioned, which greatly reduces the construction time of tensioning construction, improves the work efficiency of tensioning, and the synchronous tensioning of multiple carbon plates reduces the exposure time of workers in the high-stress state of carbon plates, greatly improving the safety of the tensioning process.

[0015] 2. Quality improvement results: 1. The synchronous system is used for tensioning, and the synchronous system can realize real-time data acquisition and real-time monitoring of elongation, so that the tensioning reading in the previous construction is changed from manual control to equipment control, reducing human error; 2. Synchronous tensioning can simultaneously tension the whole span or even multiple spans, and the stress of each beam structure of the bridge is synchronously increased, so that synchronous tensioning avoids uneven stress in the tensioning process, and also plays a safety guarantee role for the structural safety of the bridge.

[0016] 3. Economic results: after the subsequent process is completely mature, the construction quality can be precisely controlled through the improvement and optimization of the process, the use of labor can be greatly reduced, the management can be realized in real time, and the comprehensive benefits and economic benefits will be greatly improved.

[0017] 4. Technological Innovation Achievements: The technological innovation of the synchronous tensioning process for prestressed carbon fiber plates requires the optimization and improvement of the prestressed anchor system and the materials of the prestressed carbon fiber plates. This technological advancement leads to innovation and upgrading of the entire industry chain. Furthermore, this innovative process can be integrated with an intelligent prestressed anchor system to achieve real-time monitoring of the prestressed carbon fiber plates, representing a significant revolutionary advancement in prestressed carbon fiber plate construction technology.

[0018] The present invention will be described in more detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0019] The following is a brief explanation of the contents of each of the accompanying drawings and the markings in the drawings:

[0020] Figure 1 This is a schematic diagram of the present invention;

[0021] Figure 2 This is a schematic diagram of the control unit box of this utility model;

[0022] The following are labeled in the diagram: 1. Control unit box; 11. Hydraulic pump station signal connector; 12. Solenoid valve group signal connector; 13. Displacement signal connector; 2. Solenoid valve group; 21. Pressure sensor; 22. Valve group signal connector; 23. Solenoid directional valve; 3. Servo hydraulic pump station; 4. Cylinder return separation valve; 5. Displacement sensor; 6. High-pressure cylinder; 7. Tensioning end fixture; 8. Pressure plate; 9. Fixed end fixture; 10. Steel cable; Detailed Implementation

[0023] The following description, with reference to the accompanying drawings, further details the specific implementation methods of this utility model, including the shape and structure of each component, the relative positions and connections between the parts, the function and working principle of each part, the manufacturing process, and the operation and use methods, so as to help those skilled in the art to have a more complete, accurate, and in-depth understanding of the utility model concept and technical solution.

[0024] Figure 1 The bridge composite box girder prestressed carbon steel plate synchronous tensioning system shown includes a control main unit 1, a solenoid valve group 2, a servo hydraulic pump station 3, and a working unit; wherein:

[0025] The working part includes a high-pressure hydraulic cylinder 6, a tensioning end fixture 7, a fixed end fixture 9, and a steel cable 10. The two ends of the steel cable 10 are connected to the tensioning end fixture 7 and the fixed end fixture 9, respectively. The high-pressure hydraulic cylinder 6 is installed on the side of the tensioning end fixture 7, and a displacement sensor 5 is provided on the side wall of the high-pressure hydraulic cylinder 6.

[0026] The control unit box 1 is equipped with a hydraulic pump station signal connector 11, a solenoid valve group signal connector 12, and a displacement signal connector 13. The control unit box 1 establishes signal connections with the solenoid valve group 2, the servo hydraulic pump station 3, and the working part through the solenoid valve group signal connector 12, the hydraulic pump station signal connector 11, and the displacement signal connector 13, respectively.

[0027] After the solenoid valve group 2 and the servo hydraulic pump station 3 are connected by signal, they are then connected to the working parts respectively.

[0028] With the above settings, displacement sensor 5 monitors the tension force and elongation of the prestressed carbon plate in real time. The sensor data will be transmitted to the control system in the control host box in real time for control and analysis of the tensioning process.

[0029] The control system uses an advanced programmable logic controller (PLC) as the core control unit, which has high reliability and stability. It is also equipped with a touch screen display, which has a user-friendly interface, making it easy for operators to set tensioning parameters, monitor the tensioning process, and view historical data. The control system also has both automatic and manual control modes to meet the needs of different working conditions.

[0030] The servo hydraulic pump station 3 provides a stable power source for the high-pressure cylinder 6, and adopts advanced hydraulic control technology to ensure stable system pressure and rapid response;

[0031] The circuit of the servo hydraulic pump station 3 is equipped with a cylinder return separation valve 4.

[0032] Multiple working units can be set up in parallel on the system.

[0033] The working unit may include N units, each of which is controlled by the control host box 1 to realize the operation of each high-pressure oil cylinder 6; the working unit is also equipped with a network interface to connect to the control system for displacement monitoring and pressure control;

[0034] The surface of the steel cable 10 is covered with a pressure plate 8.

[0035] The solenoid valve assembly 2 includes an oil pipe joint, a solenoid directional valve 23, a valve assembly signal connector 22, and a pressure sensor 21. The solenoid valve assembly 2 is connected to the servo hydraulic pump station 3 through the oil pipe joint, the solenoid valve assembly signal connector 22 is connected to the control host box 1, and the solenoid valve assembly 2 is connected to the high-pressure oil cylinder 6 of the working part through a pipeline. The pressure sensor 5 is installed on the pipeline to monitor the oil pressure.

[0036] Working principle and method

[0037] (1) Determination of bridge composite box girder reinforcement design scheme: Based on the inspection of the bridge structure that has been in service for many years, combined with the actual defects of the bridge itself (including cracks, damage, prestress loss, etc.), the bridge grade is evaluated according to the bridge inspection results, and then the design calculation is carried out. The bridge reinforcement design scheme is determined based on the calculation results.

[0038] (2) Determination of the number of prestressed carbon plate anchors: Based on the reinforcement technical scheme obtained above, determine the number of box girders that need to be reinforced by prestressed carbon plates, and then calculate the number N of prestressed carbon plate anchors in the synchronous tensioning system of the prestressed carbon plate according to the tension stress requirements of the beam to be reinforced.

[0039] (3) Positioning and connection of prestressed carbon plate anchors: According to the construction requirements, lay out the design drawings on the surface of the beam to be reinforced, determine the position of each carbon fiber plate in the prestressed carbon plate anchor, as well as the tension end fixture and the fixed end fixture. The two ends of the carbon fiber plate are respectively connected to the corresponding fixed end anchor position, and connected to the tension end anchor through a high-strength tensioning bolt.

[0040] (4) Connection of the synchronous tensioning system of prestressed carbon plate: a high-pressure oil cylinder is provided at the tensioning end of each prestressed carbon plate anchor, and the high-pressure oil cylinder is aligned with the center of the carbon fiber plate.

[0041] (5) Parameter setting: The system is powered on and enters the parameter setting page. Combined with the technical parameters required by the design drawings, input the response parameters. The system automatically calculates the graded tensile stress and other parameters based on the input parameters. After input, the technical indicators are checked and calibrated.

[0042] (6) Manual control positioning and carbon plate pretensioning: Install anchor plates and ensure that the center lines of the fixed end anchor plates and the tensioning end anchor plates are consistent. Then connect the fixed end fixture and the tensioning end fixture to the anchor plates with steel cables. Finally, switch the equipment to the pretensioning program or manual mode, and perform the pretensioning step in the pretensioning value setting box. Set the pretensioning tension stress to 1-5KN, and tighten the carbon fiber plate to the initial pretensioning state so that the state of the stretched carbon fiber plate is parallel to the bottom of the bridge.

[0043] (7) Pre-tensioning: First, select the tensioning mode on the main interface of the control system. Choose between manual and automatic modes. In automatic tensioning mode, press the start button. The system will start tensioning in stages according to the set parameters. Stages 1-20: Apply stress to the component along the tensile direction of the structure to start pre-work. After the system tension reaches the single-stage set value, the system will automatically start holding the load. After the holding time is reached, the system will automatically start the next stage of tensioning. After the designed tension stress is completed, the system will automatically stop and hold the load safely. After the holding is completed, the pre-tensioning step is completed. After the pre-tensioning is completed, check again whether the carbon plate of the anchor is intact after being stressed. After confirming that it is intact, proceed to the next step.

[0044] (8) Formal tensioning: Set parameters on the main interface of the control system and perform automatic tensioning operation consistent with the pre-tensioning process. The synchronous tensioning system is divided into M-stage tensioning and setting tensioning data from 1% to 100%. Pre-enter the required M-stage tensioning and the tension required for each stage on the process parameter interface. After selecting the automatic mode, the status display is consistent with the selected mode. Press the start button and use the control system to start synchronous tensioning operation on each carbon fiber plate, and monitor the displacement and tensile movement in real time to ensure that the cylinder has sufficient tensioning space. Perform tensioning operation step by step according to the process requirements until the last stage is completed. After each stage of tensioning is completed, the condition of the carbon fiber plate should be observed for at least 1-5 minutes. After reaching 100% tension stress level, the load should be held for at least 5 minutes for observation.

[0045] During automatic tensioning operations, tensioning is performed step by step with reference to tensioning parameters. The tensioning stages can be divided into 1 to 100 stages.

[0046] (9) After all stages are completed, fill with adhesive to repair, maintain a neat appearance, and remove the tensioning equipment after the design time.

[0047] The present invention has been described above with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A synchronous tensioning system for prestressed carbon fiber plates in bridge composite box girders, characterized in that, It includes a control unit, solenoid valve assembly, servo hydraulic pump station, and working section; among which: The working part includes a high-pressure hydraulic cylinder, a tensioning end fixture, a fixed end fixture, and a steel cable. The two ends of the steel cable are connected to the tensioning end fixture and the fixed end fixture, respectively. The high-pressure hydraulic cylinder is installed on the side of the tensioning end fixture, and a displacement sensor is provided on the side wall of the high-pressure hydraulic cylinder. The control unit is equipped with a hydraulic pump station signal connector, a solenoid valve group signal connector, and a displacement signal connector. The control unit establishes signal connections with the solenoid valve group, the servo hydraulic pump station, and the working part through the solenoid valve group signal connector, the hydraulic pump station signal connector, and the displacement signal connector, respectively. After the solenoid valve assembly and the servo hydraulic pump station are connected by signal, they are then connected to the working parts respectively.

2. The synchronous tensioning system for prestressed carbon fiber plate in a bridge composite box girder according to claim 1, characterized in that, The servo hydraulic pump station is equipped with a cylinder reflux separation valve in its circuit.

3. The synchronous tensioning system for prestressed carbon fiber plate in a bridge composite box girder according to claim 1, characterized in that, Multiple working units may be provided and connected in parallel on the system.

4. The synchronous tensioning system for prestressed carbon fiber plates in a bridge composite box girder according to claim 3, characterized in that, The surface of the steel cable is covered with a pressure plate.

5. The synchronous tensioning system for prestressed carbon fiber plates in a bridge composite box girder according to claim 1, characterized in that, The solenoid valve assembly includes an oil pipe joint, a solenoid directional valve, a valve assembly signal connector, and a pressure sensor. The solenoid valve assembly is connected to the servo hydraulic pump station through the oil pipe joint, and the solenoid valve assembly signal connector is connected to the control host box. The solenoid valve assembly is connected to the high-pressure oil cylinder of the working part through a pipeline, and the pressure sensor is installed on the pipeline to monitor the oil pressure.

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