Automatic control and over-filling early warning device for pile top elevation of cast-in-place pile

Abstract

The utility model discloses a kind of bored pile pile top elevation automatic control and overfill early warning device, it is related to bored pile overfill early warning technical field, including float, guide embedded tendon, PLC control box, alarm, ultrasonic range finder and top support plate, float is slidably sleeved on guide embedded tendon, the top of guide embedded tendon can be dismantled and installed on top support plate, PLC control box, alarm is installed on the top surface of top support plate, ultrasonic range finder is installed on the bottom surface of top support plate.The device is through the linkage mechanism of guide embedded tendon and float, the displacement change of concrete surface is converted into measurable mechanical displacement, the distance between concrete top surface and top support plate is monitored in real time by ultrasonic range finder, and data is transmitted to PLC control box, by mechanical transmission and ultrasonic ranging technology are combined, the accurate control of concrete pouring quantity is realized, the problem such as the precision deficiency of traditional weight measurement and measuring rope measurement etc. is solved.

Description

Technical Field

[0001] This utility model relates to the field of cast-in-place pile construction technology, specifically to an automatic control device for the top elevation of cast-in-place piles and an over-pouring early warning device. Background Technology

[0002] With rapid urbanization, high-rise buildings and underground space development are increasing, making deep foundation pit engineering commonplace. As a key form of deep foundation pit support and foundation engineering, the construction quality of cast-in-place piles directly affects the safety of the entire project. A long-standing problem in cast-in-place pile construction is the inaccurate control of the pile top elevation. The closest solution in the existing technology is the "density hammer-measuring rope" measuring device disclosed in Chinese patent CN204385780U. However, it can only perform discrete single-point measurements during the intermittent pouring period and cannot output real-time elevation change signals as the concrete liquid level rises continuously. Moreover, it does not have any alarm unit. When the concrete liquid level reaches or exceeds the designed over-pouring threshold, the system cannot actively issue a stop-pouring command to the operator, resulting in large dispersion of over-pouring height and serious material waste. Each measurement requires manual lifting and retrieving of the measuring rope, which reduces construction efficiency and introduces human reading errors. The swinging of the measuring rope in the mud environment and the eccentric contact of the density hammer make the repeated measurement error generally greater than ±50mm, which cannot meet the accuracy requirement of ±3mm for the pile top elevation of the current industry standard "Technical Specification for Building Pile Foundations" (JGJ 94-2008).

[0003] Therefore, how to provide a device that can automatically and accurately control the pile top elevation and provide early warning of over-irrigation is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0004] The purpose of this invention is to solve the problems of inaccurate control of pile top elevation, inconsistent over-pouring height, material waste, and reduced construction quality in existing cast-in-place pile construction technology, and to provide an automatic control and over-pouring early warning device for the pile top elevation of cast-in-place piles.

[0005] This utility model is achieved through the following technical solution: An automatic control and over-grouting early warning device for the top elevation of cast-in-place piles includes a floating roof, guide pre-embedded bars, a PLC control box, an alarm, an ultrasonic rangefinder, and a top support plate. A bottom support plate is fixed to the bottom end of the guide pre-embedded bars. A central through hole is formed at the center of the floating roof, through which the floating roof slides onto the guide pre-embedded bars, with the bottom of the floating roof abutting against the bottom support plate. An installation through hole is formed on the top support plate, and an upwardly extending locking tube is fixed around the installation through hole on the top surface of the top support plate. Multiple compression seams are evenly distributed on the locking tube. The top part passes through the mounting hole and is inserted into the locking tube. The locking tube is threaded with a locking sleeve, which locks and fixes the top part of the guide embedded bar inside the locking tube. The PLC control box and alarm are installed on the top surface of the top support plate, and the ultrasonic rangefinder is installed on the bottom surface of the top support plate. Both the alarm and the ultrasonic rangefinder are electrically connected to the PLC control box. The ultrasonic rangefinder measures the concrete elevation in real time and transmits the data to the PLC control box. When the concrete is about to reach or reaches the over-pouring value, the PLC control box controls the alarm to sound, thereby realizing automatic control.

[0006] As a preferred embodiment of this utility model, the top support plate is made of rectangular steel plate and has hooks on it.

[0007] As a preferred embodiment of this utility model, four hooks are provided and are respectively connected to the four corners of the top support plate.

[0008] As a preferred embodiment of the present invention, the hook includes a hook body section and a hook body section. The hook body section is attached to the top surface of the top support plate, and the hook body section is fixed to the outer end of the hook body section and extends to the outside of the top support plate. The hook body section has an elongated adjustment hole, and a fastening bolt is inserted into the elongated adjustment hole. The fastening bolt is threadedly connected to the top support plate, and the fastening bolt locks and fixes the hook body section to the top support plate.

[0009] As a preferred embodiment of this utility model, the outer surface of the guide embedded rib is designed to be smooth.

[0010] As a preferred embodiment of this utility model, the floating platform is made of stainless steel, with a convex bottom surface, a flat top surface, and a hollow interior.

[0011] As a preferred embodiment of this utility model, the alarm is an audible and visual alarm.

[0012] This invention utilizes a linkage mechanism between the guide embedded bars and the floating platform to convert the displacement changes of the concrete surface into measurable mechanical displacement. An ultrasonic rangefinder mounted on the top support plate monitors the distance between the floating platform and the top support plate in real time and transmits the data to a PLC control box. The PLC control box has a built-in comparison and calculation program that processes the data. When the concrete pouring height reaches the preset elevation, an alarm is triggered, emitting an audible and visual alarm, allowing construction personnel to conveniently stop further concrete pouring. This invention, by combining mechanical transmission with ultrasonic ranging technology, achieves precise control of the concrete pouring volume, minimizing the workload of subsequent pile head removal and solving the problems of insufficient accuracy in traditional methods such as hammer measurement and rope measurement. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0014] Figure 2 This is a schematic diagram of the bottom surface of the top support plate in this utility model.

[0015] Figure 3 This is a schematic diagram of the structure of the floating plate abutting against the bottom support plate in this utility model.

[0016] Figure 4 This is a schematic diagram of the locking tube and locking sleeve in this utility model.

[0017] Figure 5 This is a schematic diagram of the hook structure in this utility model.

[0018] In the diagram: 1. Floating roof; 2. Guide embedded rib; 3. PLC control box; 4. Alarm; 5. Hook; 6. Top support plate; 7. Bottom support plate; 8. Ultrasonic rangefinder; 9. Locking tube; 10. Extrusion joint; 11. Locking sleeve; 12. Long strip adjustment hole; 13. Fastening bolt. Detailed Implementation

[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0020] This utility model provides an automatic control device for the top elevation of cast-in-place piles and an over-grouting early warning device, such as... Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5As shown, it includes a floating roof 1, guide embedded ribs 2, PLC control box 3, alarm 4, ultrasonic rangefinder 8, and top support plate 6.

[0021] The floating roof 1 is made of stainless steel, with a convex bottom and a flat top to increase buoyancy and reduce the seepage of concrete slurry.

[0022] The bottom end of the guide embedded bar 2 is fixed with a bottom support plate 7. A central through hole is opened at the center of the floating plate 1. The floating plate 1 is slidably fitted onto the guide embedded bar 2 through the central through hole, and the bottom of the floating plate 1 abuts against the bottom support plate 7. The bottom support plate 7 is used to support the floating plate 1 and restrict its downward sliding. The contact surface between the bottom support plate 7 and the floating plate 1 is a horizontal annular support surface. The outer surface of the guide embedded bar 2 is designed with a smooth surface to facilitate the sliding of the floating plate 1 on it. The guide embedded bar 2 is the vertical guide rod of the floating plate 1 and also serves as the permanent main reinforcement of the cast-in-place pile. After the construction is completed, the guide embedded bar 2 is left in the pile body to continue to bear the load as the permanent main reinforcement of the pile body, realizing the integration of guidance, measurement and load bearing functions.

[0023] The top support plate 6 is made of rectangular steel plate. The top support plate 6 has an installation through hole. A locking tube 9 extending upward is fixed around the installation through hole on the top surface of the top support plate 6. Multiple extrusion slits 10 are evenly distributed on the locking tube 9. The top part of the guide pre-embedded rib 2 passes through the installation through hole and is inserted into the locking tube 9. The locking tube 9 is threaded with a locking sleeve 11. The locking sleeve 11 locks and fixes the top part of the guide pre-embedded rib 2 in the locking tube 9.

[0024] The PLC control box 3 and the alarm 4 are installed on the top surface of the top support plate 6, and the ultrasonic rangefinder 8 is installed on the bottom surface of the top support plate 6. Both the alarm 4 and the ultrasonic rangefinder 8 are electrically connected to the PLC control box 3. The alarm 4 uses an audible and visual alarm for better warning effect. The ultrasonic rangefinder 8 measures the concrete elevation in real time and transmits the data to the PLC control box 3 to achieve automatic control. Specifically, the ultrasonic rangefinder 8 emits ultrasonic waves to the top surface of the floating roof 1 and receives the echoes. The PLC control box 3 calculates the real-time distance L based on the echo time t. When L ≤ the preset over-pouring threshold L0, it outputs a switch signal to trigger the alarm 4, forming a dynamic closed-loop control of the floating roof, ultrasonic waves, and PLC. Four hooks 5 are provided on the top support plate 6 for connecting and fixing to the reinforcing cage. The four hooks 5 are respectively connected to the four corners of the top support plate 6. The hooks 5 are made of high-strength steel and are L-shaped. They include a hook body section and a hook body section. The hook body section is attached to the top surface of the top support plate 6, and the hook body section is fixed to the outer end of the hook body section and extends to the outside of the top support plate 6. The hook body section has an elongated adjustment hole 12, and a fastening bolt 13 is inserted into the elongated adjustment hole 12. The fastening bolt 13 is threaded to the top support plate 6, and the fastening bolt 13 locks the hook body section to the top support plate 6. In use, the hooks 5 can flexibly hook the reinforcing cage at the pile hole opening. The length of the hooks 5 is adjustable, with an adjustment range of 50~200mm to adapt to different construction conditions. The hooks 5 at the four corners are evenly stressed to ensure the stability and reliability of the top support plate 6 during construction. Bolt holes are reserved at the corners of the top support plate 6, and the hooks 5 are fixed by the fastening bolts 13 for easy disassembly and adjustment.

[0025] The construction process of cast-in-place piles using the automatic control and over-grouting early warning device for pile top elevation described in this embodiment is as follows: The process includes: forming the bored pile → fabricating the reinforcing cage (including assembling the guide embedded bars 2) → lowering the reinforcing cage and lower components (including the floating plate 1 and the guide embedded bars 2) → installing and fixing the upper components (including assembling and fixing the PLC control box 3, the alarm 4, the hook 5, the ultrasonic rangefinder 8, the top support plate 6, etc.) → setting preset parameters → pouring concrete → real-time monitoring and over-pouring early warning → stopping the pouring → dismantling the device in this embodiment.

[0026] In the above process flow, during the installation of the device in this embodiment, the floating plate 1 and the guide embedded bar 2 are extended into the pile hole along the depth direction of the steel cage. The top support plate 6 is hooked onto the steel cage at the pile hole opening by the hooks 5 at its four corners. The hooks 5 at the four corners are evenly stressed, ensuring the stability and reliability of the top support plate 6 during the construction process.

[0027] In the above process flow, when dismantling the device in this embodiment, the locking sleeve 11 on the top support plate 6 is rotated off the locking tube 9, and the top part of the embedded bar 2 is released from the locking tube 9. Then the top support plate 6 can be removed from the embedded bar 2, and the floating plate 1 can be taken out. The embedded bar 2 is then cast into the concrete pile as the embedded steel bar of the cast-in-place pile. In order to further ensure that the floating plate 1 can be taken out smoothly, a pull line can be connected between the floating plate 1 and the top support plate 6, and the floating plate 1 can be taken out smoothly by pulling the line.

[0028] Regarding the above-described process, the early warning principle of the device described in this embodiment is as follows: As concrete is poured, its height gradually increases, and the floating plate 1 suspended on the concrete surface rises slowly accordingly. During this process, as the floating plate 1 rises, the transmitting end of the ultrasonic rangefinder 8 continuously emits ultrasonic waves downwards. The ultrasonic waves are reflected after encountering the floating plate 1, and the receiving end of the ultrasonic rangefinder 8 receives the echo reflected from the surface of the floating plate 1. By measuring the round-trip time of the ultrasonic waves, the distance from the floating plate 1 to the top support plate 6 is accurately calculated. The ultrasonic rangefinder 8 transmits the real-time measured distance data to the PLC control box 3 fixed on the top support plate 6. The PLC control box 3 has a pre-programmed comparison and operation logic control program. Based on the real-time distance data, combined with the initially set position of the floating plate 1 and the target elevation, the concrete pouring height is calculated. When the concrete pouring height reaches the preset control height, it is determined that the preset condition has been met. At this time, the PLC control box 3 sends a control signal, triggering the alarm 4 to issue an audible and visual alarm. Upon receiving the alarm, the operator immediately stops pouring concrete.

[0029] To verify the accuracy of this device, three bored piles with a diameter of 800mm and a mud specific gravity of 1.25 g / cm³ were selected on site and compared with those measured manually using this device. The results showed that the pile top elevation errors were +8mm, -5mm, and +6mm, all less than ±10mm, meeting the ±30mm requirement of JGJ 94-2008, and no over-pouring exceeding 0.15m was observed.

[0030] This embodiment of the device uses automatic program control to precisely adjust the pile top elevation and over-grouting height, ensuring that the pile top elevation and effective pile length meet design and specification standards. This device optimizes the earthwork excavation process, improves construction efficiency, and reduces material waste while ensuring the integrity of the pile body. This invention aims to solve the technical problems in existing cast-in-place pile construction that rely on manual measurement, leading to inaccurate pile top elevation control, inconsistent over-grouting height, material waste, and the risk of pile breakage due to uneven pile heads.

[0031] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. An automatic control and over-irrigation early warning device for the top elevation of cast-in-place piles, characterized in that: The system includes a floating roof (1), guide pre-embedded bars (2), a PLC control box (3), an alarm (4), an ultrasonic rangefinder (8), and a top support plate (6). The guide pre-embedded bars (2) are the permanent main reinforcing bars of the cast-in-place pile and also serve as the vertical guide rods of the floating roof (1). A bottom support plate (7) is fixed at the bottom end of the guide pre-embedded bars (2). A central through hole is provided at the center of the floating roof (1). The floating roof (1) slides on the guide pre-embedded bars (2) through the central through hole, and the bottom of the floating roof (1) abuts against the bottom support plate (7). An installation through hole is provided on the top support plate (6), and the top surface of the top support plate (6) is fixed around the installation through hole. There is an upwardly extending locking tube (9), and multiple extrusion seams (10) are evenly distributed on the locking tube (9). The top part of the guide pre-embedded rib (2) is inserted into the locking tube (9) after passing through the installation through hole. The locking tube (9) is connected to a locking sleeve (11) by external thread. The locking sleeve (11) locks and fixes the top part of the guide pre-embedded rib (2) in the locking tube (9). The PLC control box (3) and the alarm (4) are installed on the top surface of the top support plate (6), and the ultrasonic rangefinder (8) is installed on the bottom surface of the top support plate (6). The alarm (4) and the ultrasonic rangefinder (8) are both electrically connected to the PLC control box (3).

2. The automatic control and over-irrigation early warning device for the top elevation of cast-in-place piles according to claim 1, characterized in that: The top support plate (6) is made of rectangular steel plate and has hooks (5) on it.

3. The automatic control and over-irrigation early warning device for the top elevation of cast-in-place piles according to claim 1, characterized in that: There are four hooks (5), which are respectively connected to the four corners of the top support plate (6).

4. The automatic control and over-irrigation early warning device for the top elevation of cast-in-place piles according to claim 3, characterized in that: The hook (5) includes a hook body section and a hook body section. The hook body section is attached to the top surface of the top support plate (6). The hook body section is fixed to the outer end of the hook body section and extends to the outside of the top support plate (6). The hook body section has an elongated adjustment hole (12). A fastening bolt (13) is inserted into the elongated adjustment hole (12). The fastening bolt (13) is threadedly connected to the top support plate (6). The fastening bolt (13) locks the hook body section onto the top support plate (6).

5. The automatic control and over-grouting early warning device for the top elevation of cast-in-place piles according to any one of claims 1-4, characterized in that: The outer surface of the guide embedded bar (2) is designed to be smooth.

6. The automatic control and over-irrigation early warning device for the top elevation of cast-in-place piles according to claim 5, characterized in that: The floating platform (1) is made of stainless steel, with a convex bottom, a flat top, and a hollow interior.

7. The automatic control and over-irrigation early warning device for the top elevation of cast-in-place piles according to claim 6, characterized in that: The alarm (4) adopts an audible and visual alarm.

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