Assembly device for prefabricated components of bridge deck systems

Abstract

An assembly device for prefabricated components of bridge deck systems, characterized in that the assembly device comprises a fixed portal (1) and a movable portal (101), the fixed portal (1) comprising an outer column head support (105), the movable portal (101) comprising a foldable column head support (104), and the outer column head support (105) is connected to the foldable column head support (104); an outer extendable support (4) and a middle support (5) are arranged at each of the two lower ends of the outer column head support (105), an inner support (6) being arranged at the lower end of the foldable column head support (104), which inner support has an inner support base (602) and an inner drive wheel (601) on the lower side, and the middle support (5) has a middle support base (502) and a middle drive wheel (501) on the lower side;on the outer column head support (105) and the foldable column head support (104) rails (103) are arranged, on which a mobile carriage (2) is arranged, wherein a winch (205) is arranged on the mobile carriage (2), and the winch (205) is connected to a lifting frame (3);

Description

Technical field

[0001] The present invention belongs to the field of construction technology and relates in particular to an assembly device for prefabricated components of bridge deck systems. State of the art

[0002] In high-speed railway construction, a bridge deck system structure is located on both sides of the bridge. This system consists of two cable ducts for laying high-voltage and low-voltage cables. The cross-section is "mountain-shaped," with high walls on the sides and a lower wall in the middle. The floor is made of concrete of a certain thickness, and pavement slabs are laid along the track between the two sidewalls, serving as a pedestrian walkway. The construction of such bridge deck systems was originally carried out using cast-in-place concrete construction with formwork. Later, the outer walls were manufactured and installed as prefabricated fascias. In recent years, a prefabricated assembly method has been developed for the entire "mountain-shaped" bridge deck system, with a standard spacing of 2 meters.The assembly method involves transporting the prefabricated components to the construction site by a mobile crane, roughly positioning them, then aligning them with special lifting equipment and fastening them with bolts. The gap between the lower part and the beam is filled by grouting. The entire assembly process is manual, which makes alignment difficult, reduces work efficiency, and prolongs the construction process. At the same time, the beam transport trolley continues to operate, and the lifting device must stop at the edge of the beam to avoid the beam transport trolley, which poses a significant safety risk. Due to practical construction requirements, a device that automatically enables lifting, precise positioning, and avoiding the beam transport trolley is required.

[0003] The patent publication number CN109972520A, published on July 5, 2019, describes a construction method for the assembly structure of a prefabricated bridge deck. The construction method includes the following steps: 1) Preparation of the construction work; 2) Manufacturing of the structural components; 3) Lifting and positioning the prefabricated bridge deck; 4) Installing the cantilever connection structure; 5) Grouting the middle joints; 6) Grouting the joints at the cantilever end; 7) Erecting the protective element foundations and posts. This assembly method cannot improve the safety and precision of the assembly. Summary of the invention

[0004] The present invention is based on the object of remedying the deficiencies of the existing technology and providing an assembly device for prefabricated components of bridge deck systems that are easy to operate, safe and precise in assembly positioning.

[0005] To achieve the above objects, the invention provides the following technical features: The assembly device for prefabricated components of bridge deck systems comprises a fixed gantry and a movable gantry. The fixed gantry comprises an outer column header, and the movable gantry comprises a foldable column header connected to the outer column header. An outer extendable support and a middle support are arranged at both lower ends of the outer column header. At the lower end of the foldable column header is an inner support, which is provided with an inner support base and an inner drive wheel at the lower end. The middle support is provided with a middle support base and a middle drive wheel at the lower end. Rails are arranged on the outer column header and the foldable column header, on which a mobile carriage is mounted. A winch is arranged on the mobile carriage and is connected to a lifting frame.

[0006] The mobile carriage comprises a running beam, which is laterally equipped with a drive motor. The running beam interacts with the rails, and a longitudinal beam is arranged between the running beams, on which slideways are arranged. The rails and slideways are arranged orthogonally to each other. A mounting base is arranged on the slideways, which interacts with the slideways at the bottom. The winch is mounted on the mounting base, and a first hydraulic cylinder is arranged laterally on the mounting base. Four slideways are provided, which are evenly spaced, and a mounting base is arranged at each end of the rails. Four winches and two lifting frames are provided.

[0007] The lifting frames are arranged horizontally and have symmetrically arranged lifting holes at the top that are connected to the winches. The lifting frames are equipped with rails on the inside and a second hydraulic cylinder in the center, which includes an inclination sensor. A first extendable frame and a second extendable frame are located at each end of the lifting frame. The second hydraulic cylinder is connected to the first extendable frame and the second extendable frame at each end. The first extendable frame and the second extendable frame are each operatively connected to the rails at the top. The first extendable frame and the second extendable frame each have a bolt hole on the side into which a bolt is inserted.

[0008] The middle drive wheel is located at the bottom end of the middle support and is connected to a first drive motor. The middle support base is located to one side of the middle drive wheel, and the middle drive wheel is connected to a first hydraulic rod at the top end. The inner drive wheel is located at the bottom end of the inner support and is connected to a second drive motor. The inner support base is located to one side of the inner drive wheel, and the inner drive wheel is connected to a second hydraulic rod at the top end. Between the inner drive wheel and the inner support is a rotating base connected to a third drive motor.

[0009] A pivot axis and an automatic latch are located on both sides of the outer column head support. The outer column head support is connected to the folding column head support via the pivot axis, and the fixed portal is hinged to the movable portal.

[0010] The length of the rails is greater than the distance between the outer telescopic support and the inner support. A limit block is located at the upper end of the outer column head support, and a guide plate is located at the lower end of the first telescopic frame.

[0011] Beneath the mobile carriage is a prefabricated component with a lifting hole on its side. The bolt penetrates the bolt hole and engages the lifting hole. The first extendable frame rests on one side of the prefabricated component, and the second extendable frame rests on the other side. In the center of the lower end of the lifting frame is a support, the lower end of which rests against the top of the prefabricated component.

[0012] Prefabricated components equipped with an auxiliary laser sensor are arranged on the bridge surface. A first laser sensor is located at the lower end of the support, and a second laser sensor is located at the lower end of the first extendable frame.

[0013] Guide wheels are arranged on the side of the central support, arranged in pairs and resting against the side of the prefabricated components that have already been assembled.

[0014] The assembly procedure for prefabricated components of bridge deck systems is carried out using the assembly device for prefabricated components of bridge deck systems described above and includes the following steps: S1: Moving the device to the assembly position of a prefabricated component, adjusting the outer extendable supports so that they rest on the already assembled prefabricated component, and activating the support bases to establish ground contact; S2: Attaching an auxiliary laser sensor to one end of the B-wall of the already assembled prefabricated component, transporting the prefabricated component by a component transport trolley under the lifting frame and adjusting a mobile trolley to align it with the prefabricated component; S3: Activate the first hydraulic cylinder to increase the distance between the two lifting frames and activate the winch to lower the lifting frame until the bolt hole is aligned with the lifting hole; S4: Activating the second hydraulic cylinder to reduce the distance between the lifting frames so that the first extendable frame and the second extendable frame each rest against one side of the prefabricated component, and inserting the bolt into the bolt hole and the lifting hole; S5: Activate the winch to lift the prefabricated component and activate the mobile carriage until it rests against the limit block; S6: Activate the winch to lower the prefabricated component until the set distance is reached, then stop the winch; S7: Activate the mobile carriage to move towards the center of the bridge until the set distance is reached, then stop the movement; S8: Fine adjustment of the tilt sensor by the winch to bring the prefabricated component into a horizontal position; S9: Activate the first hydraulic cylinder to move the four mounting bases synchronously to the specified distance and stop the movement; S10: Removal of the bolt, placement of the prefabricated component and placement of supports; S11: Resetting the trolley, the lifting frame and the winch, and installing anchor bolts to fix the prefabricated component; S12: Retract the support bases to bring the drive wheels into contact with the ground and move the device to the next working position; S13: Repeat steps S1 to S12 to complete the assembly process of the prefabricated components.

[0015] The technical effect of the present invention is that the assembly device for prefabricated components of bridge deck systems enables a reasonable transportation method and alignment of the prefabricated components through a rational structural design. The design of the gantry, the mobile carriage and its components, and the lifting frame not only realizes the lifting and lowering process of the prefabricated components, but also the position adjustment of the prefabricated components, thereby meeting the movement requirements during the assembly and alignment process. The integration of multiple laser sensors reduces the difficulty of aligning the prefabricated components and increases the precision of assembly positioning.The design of the foldable movable gantry reduces the space required by the device according to the on-site working conditions, enabling safe and efficient movement of the girder transport trolley and ensuring normal operation of the girder transport. The arrangement of support bases and drive wheels allows the device to switch between fixed and mobile states, greatly facilitating operation. The assembly method replaces the manual, complex, and time-consuming work process, reducing labor difficulty, ensuring coordinated and orderly assembly of prefabricated components, improving assembly accuracy, reducing workload, shortening construction time, and ensuring a safe and orderly construction process. Short description of the drawings

[0016] This description includes the following drawings. They show: Fig. 1: a perspective view of the assembly device for prefabricated components of bridge deck systems according to the present invention; Fig. 2: a side schematic view of the assembly device for prefabricated components of bridge deck systems according to the present invention; Fig. 3: a plan view of the assembly device for prefabricated components of bridge deck systems according to the present invention; Fig. 4: a side schematic view of the lifting frame according to the present invention; Fig. 5: a side schematic view of the mobile carriage according to the present invention; Fig. 6: a plan view of the lifting frame according to the present invention; Fig. 7: a side view of the operating process of the assembly device for prefabricated components of bridge deck systems according to the present invention; Fig. 8: a front view of the operating process of the assembly device for prefabricated components of bridge deck systems according to the present invention; and Fig. 9: a schematic representation of the folded structure of the assembly device for prefabricated components of bridge deck systems according to the present invention. Detailed description

[0017] In the following, the concrete embodiment of the present invention will be explained in detail with reference to the drawings and the description of the embodiments in order to provide those skilled in the art with a more comprehensive, accurate and deeper understanding of the inventive concept and the technical solution of the present invention and to facilitate its implementation.

[0018] As in Fig. 1 to 9, the assembly device for prefabricated components of bridge deck systems comprises a fixed gantry 1 and a movable gantry 101. The fixed gantry 1 comprises an outer column header 105, and the movable gantry 101 comprises a foldable column header 104 connected to the outer column header 105. An outer extendable support 4 and a middle support 5 are arranged at both lower ends of the underside of the outer column header 105. At the lower end of the foldable column header 104 is an inner support 6, which is provided with an inner support base 602 and an inner drive wheel 601. The middle support 5 is provided with a middle support base 502 and a middle drive wheel 501. Rails 103, on which a mobile carriage 2 is arranged, are arranged on the outer column header 105 and the foldable column header 104.A winch 205 is arranged on the mobile carriage 2 and is connected to a lifting frame 3.

[0019] As in Fig. As shown in Figure 2, the space for assembling the prefabricated component 8 is located under the fixed gantry 1, and the space for the transport vehicle is located under the movable gantry 101. The fixed gantry 1 and the movable gantry 101 are designed as a frame structure, and rails 103 are arranged on the outer column head beam 105 and the foldable column head beam 104. The rails 103 on the same side of the gantry are connected to form a straight line. The fixed gantry 1 and the movable gantry 101 are hinged to allow the movable gantry 101 to fold, thereby reducing the space required by the device and solving the problem of limited bridge space that makes it difficult for transport vehicles to evade. The arrangement of the support bases and drive wheels allows the device to switch between fixed and mobile states, facilitating the use of the device on the bridge.The winch 205 and the lifting frame 3 enable the lifting and lowering of the prefabricated component 8, while the horizontal movement of the prefabricated component 8 is achieved by the movement of the mobile carriage 2 on the rails 103. The longitudinal movement of the prefabricated component 8 is realized by the movement of the winch 205 along the slideways 202.

[0020] As in Fig. As shown in Figures 1 to 3, a connecting beam 606 is disposed between the inner supports 6, and a cross beam 503 is fixedly connected between the outer extendable supports 4 and the middle supports 5. An outer connecting frame 102 is disposed between the outer column head supports 105, and a movable axle 110 is disposed at the ends of the foldable column head support 104. An inner connecting frame 107 is disposed between the foldable column head supports 104 and is connected to the movable axle 110. The cross beam 503 serves as a reinforcing structure between the outer extendable supports 4 and the middle supports 5 to increase the structural strength of the support portions of the device. When the device is unfolded, the inner connecting frame 107 serves as a support structure to ensure that the two rails 103 of the device remain parallel and the traveling carriage 2 can operate smoothly.When the device is folded, the ends of the inner connecting frame 107 can be rotated about the movable axis 110 to realize the folding function.

[0021] As in Fig. 1 and Fig. As shown in Figure 5, the mobile carriage comprises two running beams 203. A drive motor 207 is arranged on the sides of the running beams 203. The running beams 203 interact with the rails 103, and a longitudinal beam 204, on which slideways 202 are arranged, is arranged between the running beams 203. The rails 103 and the slideways 202 are arranged orthogonally to one another. A mounting base 206 is arranged on the slideways 202, which interacts with the slideways 202 at the bottom. The winch 205 is mounted on the mounting base 206, and a first hydraulic cylinder 201 is arranged laterally on the mounting base 206. Four slideways 202 are provided, which are evenly spaced, and a mounting base 206 is arranged at each end of the rails 103. Four winches 205 and two lifting frames 3 are provided.The running beam 203, in cooperation with the rails 103, guides the movement of the mobile carriage 2, while the assembly base 206, in cooperation with the slideways 202, guides the winch 205. The winch 205 is connected to the lifting frame 3, and by driving the first hydraulic cylinder 201, the distance between the two lifting frames 3 is increased or decreased, which not only facilitates the positioning process of the prefabricated component 8, but also enables the assembly of prefabricated components of different lengths. The assembly bases 206 interact with the two rails 103 at the bottom to ensure the stability of the movement of the assembly bases 206 and the winch 205. Each group of winches 205 is controlled by a group of first hydraulic cylinders 201 to control the longitudinal movement, allowing for fine length adjustment during component assembly.Two winches 205 correspond to two lifting holes 301 of a lifting frame 3, and two lifting frames 3 respectively lift the two ends of the prefabricated component 8, that is, the positional movement of the prefabricated component 8 is realized by the lifting of the four winches 205, which greatly ensures the flatness and precision of the assembly.

[0022] As in Fig. 1 to 4, the lifting frames 3 are arranged horizontally and have symmetrically arranged lifting holes 301 at the top, which are connected to the winch 205. The lifting frames 3 are provided with rails 308 on the inside and a second hydraulic cylinder 309 in the center, which includes an inclination sensor. At both ends of the lifting frame 3 there are a first extendable frame 302 and a second extendable frame 303, each of which is connected to the second hydraulic cylinder 309 at both ends. The first extendable frame 302 and the second extendable frame 303 are each operatively connected to the rails 308 at the top. The first extendable frame 302 and the second extendable frame 303 are each provided with a bolt hole 305 on the side, into which a bolt 306 is inserted.

[0023] As in Fig. 4 and Fig. As shown in Figure 6, the frame of the lifting frame 3 consists of a rail support 310 and two end supports 311. The rails 308 are located on the inside of the end supports 311, and the second hydraulic cylinder 309 is attached to the center of the frame of the lifting frame 3. The two ends of the second hydraulic cylinder 309 are respectively connected to the two first extendable frames 302, which can open or close. Each first extendable frame 302 has a bolt hole 305 at the bottom, which can coincide with the lifting hole 301 of the prefabricated component 8. By inserting the bolt 306, the prefabricated component 8 is secured and can be moved with the lifting frame 3. The length of the second extendable frame 303 does not exceed the bottom of the raised prefabricated component 8. The length of the first extendable frame 302 can be extended to the bottom of the raised prefabricated component 8.The first frame 302 is provided at the bottom with a second laser sensor 313, which can detect the distance to the lateral edges of the bridge's wing plate in order to determine the lateral position of the prefabricated component 8 during assembly. The symmetrically arranged lifting holes 301 serve to ensure the stability of the prefabricated component 8. The first extendable frame 302 is T-shaped at the upper end, and the positional movement of the first and second extendable frames 302, 303 on the rails 308 is realized by the drive of the second hydraulic cylinder 309, whereby the distance between the frames 302, 303 can be increased or decreased. This not only enables the secure clamping and locking of the prefabricated component 8 during lifting, but can also be used to lift prefabricated components 8 of different widths.The tilt sensor can detect whether the component is tilted and an adjustment is made by moving the four winches 205.

[0024] As in Fig. 1 and Fig. 2, the middle drive wheel 501 is located at the lower end of the middle support 5 and is connected to a first drive motor 505. The middle support base 502 is located to the side of the middle drive wheel 501, and the middle drive wheel 501 is connected at the upper end to a first hydraulic rod 506. The inner drive wheel 601 is located at the lower end of the inner support 6 and is connected to a second drive motor 603. The inner support base 602 is located to the side of the inner drive wheel 601, and the inner drive wheel 601 is connected at the upper end to a second hydraulic rod 507. Between the inner drive wheel 601 and the inner support 6 is a rotating base 605, which is connected to a third drive motor 604. The outer extendable supports 4 are hydraulically controlled extendable structures whose lower end is connected to a support beam 401.The support beam 401 and the outer extendable supports 4 are connected by a ball joint. The middle drive wheel 501 is rotatable, and the middle support base 502 can extend and retract vertically. The middle support base 502 and the support 304 are connected by a ball joint. The inner drive wheel 601 is rotatable, and the inner support base 602 can extend and retract vertically. The inner support base 602 and the support 304 are connected by a ball joint. The ball joint connection between the above-mentioned support bases or the support beam 401 and the connected supports 304 can rotate within a certain range to compensate for slight inclinations or unevenness of the contact surface and ensure effective support on uneven support surfaces. The middle support 5 and the inner support 6 form the support structure of the entire device.By alternating between drive wheels and support bases, the device enables two operating states: mobile and stationary. When the device is used for lifting, the support bases support the entire device under hydraulic drive, while the drive wheels lose contact with the ground and can no longer absorb power, thus fixing the device and ensuring a stable lifting process. When the device is moved or transported between workstations, the support bases are raised so that the drive wheels support the entire device and enable the device to be mobile. When the device needs to be folded, the third drive motor 604 and the rotating base 605 enable the steering of the inner drive wheel 601, and the second drive motor 603 drives the inner drive wheel 601 to assist the folding process of the device.

[0025] As in Fig. 9, a pivot axis 109 and an automatic latch 108 are provided on both sides of the outer column head support 105. The outer column head support 105 is connected to the foldable column head support 104 via the pivot axis 109, and the fixed gantry 1 is pivotally connected to the movable gantry 101. The above-described structure enables the device to be folded. When the automatic latch 108 engages, the foldable column head support 104 can be rotated around the pivot axis 109 together with the inner connecting frame 107. Steps for deforming, folding, and retracting the device and notes: First, the mobile carriage 2 is moved to the outermost position of the device and stopped. Then, the inner support bases 602 of the device are hydraulically driven and automatically raised completely from the ground, so that the inner drive wheels 601 make contact with the ground.It should be noted that the outer extendable supports 4 and the middle supports 5 do not leave the ground and remain in their original, ground-contacting state. The automatic latch 108 of the device is then remotely operated to automatically remove the bolt and thus unlock the movable gantry 101. Finally, the inner drive wheels 601 are rotated by a certain angle, and the two groups of inner drive wheels 601 on the inner support 6 are set in motion, so that the movable gantry 101 moves around the rotation axis 109 toward the middle support 5 until the movable gantry 101 is automatically brought into the folded position, completing the folding and retraction of the device. By reversing the above steps, the device can be unfolded again.

[0026] As in Fig. 2, the length of the rails 103 is greater than the distance between the outer telescopic support 4 and the inner support 6. A limit block 106 is arranged at the upper end of the outer column head support 105, and a guide plate 307 is arranged at the lower end of the first telescopic frame 302. This structure facilitates positioning during the assembly of the prefabricated component 8, as follows: When the traveling carriage 2 abuts the limit block 106 and comes to a stop, the lifting frame 3 is lowered simultaneously. Since the length of the rails 103 is greater than the distance between the outer telescopic support 4 and the inner support 6, the first telescopic frame 302 is located to the side of the bridge during this process.When the traveling carriage 2 moves toward the bridge center, the guide plate 307 can abut laterally against the bridge edge, thereby aligning one side of the prefabricated component 8 with the bridge edge and completing the preliminary positioning of the prefabricated component 8. The limit block 106 serves as a limit structure for the traveling carriage 2. When one side of the traveling carriage 2 abuts the limit block 106, the lifting and lowering process of the prefabricated component 8 can be performed. At the same time, the limit block 106 prevents the traveling carriage 2 from leaving the rails 308. The bottom of the prefabricated component 8 is located above the guide plate 307 during lifting. During the lowering process, the guide plate 307 can abut laterally against the bridge edge, thereby determining the position of the prefabricated component 8.

[0027] As in Fig. 7 and Fig. 8, the prefabricated component 8, which has a lifting hole on the side, is located under the mobile carriage 2. The bolt 306 penetrates the bolt hole 305 and engages the lifting hole. The first extendable frame 302 is supported on one side of the prefabricated component 8, and the second extendable frame 303 is supported on the other side. In the center of the lower end of the lifting frame 3 is a support 304, the lower end of which rests against the top of the prefabricated component 8. The support 304 stabilizes the prefabricated component 8 and serves to mount the first laser sensor 312. The lifting hole serves as a fastening structure for the prefabricated component 8 by inserting and locking the bolt 306. The first and second extendable frames 302, 303 each rest against one side of the prefabricated component 8 and stabilize it.When the prefabricated component 8 is lifted by the lifting frame 3, the two supports 304 rest precisely on the top side of the B-wall and stabilize the prefabricated component 8, ensuring the horizontal alignment of the prefabricated component 8. The cross-section of the prefabricated component 8 is "mountain-shaped," with the center forming the B-wall. The supports 304 correspond to the position of the B-wall of the prefabricated component 8, and the first laser sensor 312 is arranged at the lower end of the supports 304, which can detect the distance to the auxiliary laser sensor 7 on the B-wall of the already assembled prefabricated component. The longitudinal positioning of the prefabricated component 8 can be realized through the automatic adjustment of the first hydraulic cylinder 201.

[0028] As in Fig. As shown in Figure 7, pre-assembled prefabricated components are arranged on the bridge surface, which are provided with an auxiliary laser sensor 7. The support 304 is provided with a first laser sensor 312 at the bottom, and the first extendable frame 302 is provided with a second laser sensor 313 at the bottom. The measuring direction of the first laser sensor 312 is perpendicular to the side of the prefabricated component 8, i.e., perpendicular to the bridge side. During the lowering process of the prefabricated component 8, the second laser sensor 313 serves to check whether the prefabricated component 8 has reached the bridge edge. When the second laser sensor 313 reaches the predetermined distance from the bridge edge, it sends a signal. The auxiliary laser sensor 7 corresponds to the first laser sensor 312, and when the prefabricated component 8 reaches the predetermined distance from the already assembled prefabricated component, the first sensor sends a signal to stop the mobile carriage 2.

[0029] As in Fig. As shown in Figure 1, guide wheels 504 are arranged in pairs on the side of the central support 5, which are in contact with the side of the already assembled prefabricated components. When the device travels longitudinally along the bridge surface, the guide wheels 504 can be in contact with the side of the already assembled components and serve as a guide. The paired arrangement of the guide wheels 504 increases the contact area with the prefabricated component 8, which further improves the accuracy of the direction of movement.

[0030] The assembly procedure for prefabricated components of bridge deck systems is carried out using the assembly device for prefabricated components of bridge deck systems described above and includes the following steps: S1: Moving the device to the assembly position of a prefabricated component 8, adjusting the outer extendable supports 4 so that they rest on the already assembled prefabricated component, and activating the support bases to establish ground contact; S2: Attaching an auxiliary laser sensor 7 to one end of the B-wall of the already assembled prefabricated component, transporting the prefabricated component 8 by a component transport trolley under the lifting frame 3 and adjusting a mobile trolley 2 to align it with the prefabricated component 8; S3: Activating the first hydraulic cylinder 201 to increase the distance between the two lifting frames 3 and activating the winch 205 to lower the lifting frame 3 until the bolt hole 305 is aligned with the lifting hole; S4: Activating the second hydraulic cylinder 309 to reduce the distance between the lifting frames 3 so that the first extendable frame 302 and the second extendable frame 303 each abut one side of the prefabricated component 8, and inserting the bolt 306 into the bolt hole 305 and the lifting hole; S5: Activating the winch 205 to lift the prefabricated component 8 and activating the mobile carriage 2 until it rests against the limiting block 106; S6: Activating the winch 205 to lower the prefabricated component 8 until the set distance is reached, then stopping the winch 205; S7: Activate the mobile carriage 2 to move towards the center of the bridge until the set distance is reached, then stop the movement; S8: Fine adjustment of the tilt sensor by the winch 205 to bring the prefabricated component 8 into a horizontal position; S9: Activate the first hydraulic cylinder 201 to synchronously move the four mounting bases 206 to the specified distance and stop the movement; S10: Remove the bolt 306, place the prefabricated component 8, and place the supports underneath; S11: Resetting the mobile carriage 2, the lifting frame 3 and the winch 205, and installing anchoring bolts to fix the prefabricated component 8; S12: Retract the support bases to bring the drive wheels into contact with the ground and move the device to the next working position; S13: Repeat steps S1 to S12 to complete the assembly process of the prefabricated components 8.

[0031] The detailed process is as follows: 1. Initial preparations: The device is moved to the intended installation position of the prefabricated component 8, with the outer extendable supports 4 of the device being extended. The undersides of the supports 304 press against the surfaces of the already installed components. All supports 304 of the device are adjusted so that they are in contact with the ground. The lower ends of the supports 304 are designed as ball joints to compensate for slight inclinations or unevenness of the contact surfaces. The auxiliary laser sensor 7 is attached to the end of the B-wall of the already installed component and must be flush with the edge. The adjusting screws on the auxiliary laser sensor 7 are adjusted so that it clamps the already installed prefabricated component. Depending on the dimensions of the component to be lifted, the four winches 205 are moved into the appropriate position using the first hydraulic cylinder 201. 2. Lifting process: After the assembly jig is stably positioned, the component transport carriage moves under the foldable column head beam 104. Then, the jig's mobile carriage 2 moves to the appropriate position of the movable gantry 101, and the lifting frame 3 is lowered. At the same time, the first extendable frame 302 of the lifting frame 3 is fully opened and lowered to the position where the bolt hole 305 is aligned with the lifting hole 301 of the prefabricated component 8. The bolt 306 of the first extendable frame 302 of the lifting frame 3 is manually aligned with the lifting holes of the component and locked. Then, the first extendable frame 302 of the lifting frame 3 is fully retracted so that the inside of each first extendable frame 302 abuts the outside of the prefabricated component 8. The mobile carriage 2 with the lifting device lifts the lifting frame 3 and the prefabricated component 8 and moves them to the appropriate position in the assembly area. 3. Assembly and adjustment of the prefabricated component 8: First, the mobile carriage 2 with the raised prefabricated component 8 moves to the limit block 106 of the device and stops, with the outermost edge of the raised prefabricated component 8 protruding approximately 40-50 mm beyond the bridge edge. Subsequently, the lifting frame 3 is slowly and smoothly lowered until the first laser sensor 312 detects the bridge edge and sends a signal. Then, the mobile carriage 2 is slowly moved toward the center of the bridge until the first laser sensor 312 detects the predetermined distance from the bridge edge and sends a signal to stop the carriage 2. At this time, the guide plate 307 under the lifting frame 3 is flush with the bridge edge. Since the inner side of the guide plate 307 is flush with the side of the prefabricated component 8 during assembly, it can be determined that the bridge edge is aligned with the outermost side of the prefabricated component 8.Subsequently, the state of the prefabricated component 8 (i.e., from inclined to horizontal) is finely adjusted using the inclination sensors respectively attached to the two lifting frames 3. Then, the prefabricated component 8 is moved by the four first hydraulic cylinders 201 toward the already assembled prefabricated component 8 until the second laser sensor 313 detects the specified distance from the auxiliary laser sensor 7 (i.e., 20 mm between the two sensors) and the movement stops. Subsequently, the lifting frame 3 is lowered until the prefabricated component 8 is in the appropriate balancing position and checked for proper support. The bolt 306 between the prefabricated component 8 and the lifting frame 3 is removed, the lifting frame 3 is fully opened, lifted, and then retracted. The anchor bolts are arranged to fix the prefabricated component 8 to the bridge.The mobile carriage 2, the lifting frame 3, and the winch 205 are reset, and the above steps are repeated along the bridge surface until the bridge deck system structure is completed. Subsequently, grouting, anchoring, and waterproofing work are carried out.

[0032] During the construction process, the fixture must be transported to another workstation. When moving the fixture, it is important to note that the mobile carriage 2 must first be moved to the center position of the fixture's movable gantry 101 and stopped, while the locking mechanism must lock the movable gantry 101 to the fixed gantry 1. The outer extendable supports 4 are retracted, the center support base 502 is retracted so that the center drive wheel 501 touches the ground. The inner support base 602 is retracted so that the inner drive wheel 601 touches the ground. The lifting frame 3 is raised to position it over the prefabricated component 8. The fixture is moved to the next workstation by the simultaneous activation of all drive wheels.During the movement, the guide wheels 504 on the middle support 5 roll along the side of the already assembled prefabricated component 8, which not only avoids friction between the middle support 5 and the side of the prefabricated component 8, but also ensures effective guidance of the device to prevent excessive skewing of the device.

[0033] The assembly device for prefabricated components of bridge deck systems enables a reasonable transportation method and routing of the prefabricated components 8 through a rational structural design. The design of the gantry, the mobile carriage 2 and its components, and the lifting frame 3 not only realizes the lifting and lowering process of the prefabricated components 8, but also the position adjustment of the prefabricated components 8, thereby meeting the movement requirements during the assembly and alignment process. The integration of multiple laser sensors reduces the difficulty of aligning the prefabricated components 8 and increases the precision of the assembly positioning.The design of the foldable movable gantry 101 allows the fixture's footprint to be reduced depending on the on-site working conditions, enabling safe and efficient movement of the girder transport trolley and ensuring normal girder transport operation. The arrangement of support bases and drive wheels allows the fixture to switch between fixed and mobile states, greatly facilitating operation. The assembly method replaces the manual, complex, and time-consuming work process, reduces work difficulty, ensures coordinated and orderly assembly of the prefabricated components 8, improves assembly accuracy, reduces workload, shortens construction time, and ensures a safe and orderly construction process.

[0034] The invention has been described above by way of example with reference to the accompanying drawings. However, it should be understood that the specific embodiment of the invention is not limited to the embodiments described above. Rather, all changes and modifications that are within the scope of the inventive idea and the scope of protection of the invention, as well as all applications of the inventive idea and the scope of protection of the invention in other fields, fall within the scope of protection of the invention. List of reference symbols 1 fixed portal 101 movable portal 102 outer connecting frame 103 rails 104 foldable column head support 105 outer column head support 106 Boundary block 107 inner connecting frame 108 automatic bolt 109 axis of rotation 110 movable axis 2 mobile carts 201 first hydraulic cylinder 202 slideways 203 running beams 204 longitudinal members 205 winds 206 mounting base 207 drive motor 3 lifting frame 301 lifting hole 302 first extendable frame 303 second extendable frame 304 Support 305 bolt hole 306 bolts 307 guide plate 308 rails 309 second hydraulic cylinder 310 rail supports 311 end support 312 first laser sensor 313 second laser sensor 4 outer extendable supports 401 support beams 5 middle support 501 middle drive wheel 502 middle support base 503 cross member 504 guide wheels 505 first drive motor 506 first hydraulic rod 6 inner support 601 inner drive wheel 602 inner support base 603 second drive motor 604 third drive motor 605 rotating base 606 connecting beams 607 second hydraulic rod 7 Auxiliary laser sensor 8 prefabricated component QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] CN 109972520A

[0003]

Claims

[1] Assembly device for prefabricated components of bridge deck systems, characterized bythat the assembly device comprises a fixed gantry (1) and a movable gantry (101), wherein the fixed gantry (1) comprises an outer column head support (105), wherein the movable gantry (101) comprises a foldable column head support (104), and the outer column head support (105) is connected to the foldable column head support (104); at both lower ends of the outer column head support (105) an outer extendable support (4) and a middle support (5) are arranged, wherein at the lower end of the foldable column head support (104) an inner support (6) is arranged, which has an inner support base (602) and an inner drive wheel (601) on the lower side, and the middle support (5) has a middle support base (502) and a middle drive wheel (501) on the lower side;on the outer column head support (105) and the foldable column head support (104) rails (103) are arranged, on which a mobile carriage (2) is arranged, wherein a winch (205) is arranged on the mobile carriage (2), and the winch (205) is connected to a lifting frame (3); [2] Assembly device for prefabricated components of bridge deck systems according to claim 1, characterized bythat the mobile carriage (2) comprises a running beam (203), wherein the running beam (203) is provided laterally with a drive motor (207), and the running beam (203) interacts with the rails (103), wherein a longitudinal beam (204) is arranged between the running beams (203), on which longitudinal beam (204) slideways (202) are arranged, and the rails (103) and the slideways (202) are arranged orthogonally to one another; a mounting base (206) is arranged on the slideways (202), wherein the mounting base (206) interacts with the slideways (202) at the bottom, and the winch (205) is arranged on the mounting base (206), and a first hydraulic cylinder (201) is arranged laterally on the mounting base (206);four slideways (202) are provided, the slideways (202) being evenly spaced, and a mounting base (206) is arranged at each end of the rails (103), four winches (205) are provided, and two lifting frames (3) are provided; [3] Assembly device for prefabricated components of bridge deck systems according to claim 2, characterized bythat the lifting frames (3) are arranged horizontally, wherein the lifting frames (3) have symmetrically arranged lifting holes (301) at the top, which are connected to the winches (205), wherein the lifting frames (3) are provided on the inside with rails (308) and are provided centrally with a second hydraulic cylinder (309), wherein the second hydraulic cylinder (309) comprises an inclination sensor;a first extendable frame (302) and a second extendable frame (303) are arranged at each of the two ends of the lifting frame (3), the second hydraulic cylinder (309) being connected at each of the two ends to the first extendable frame (302) and the second extendable frame (303), and the first extendable frame (302) and the second extendable frame (303) are each operatively connected at the top to the rails (308), the first extendable frame (302) and the second extendable frame (303) each being laterally provided with a bolt hole (305) into which a bolt (306) is inserted; [4] Assembly device for prefabricated components of bridge deck systems according to claim 3, characterized bythat the middle drive wheel (501) is arranged at the lower end of the middle support (5), wherein the middle drive wheel (501) is connected to a first drive motor (505), wherein the middle support base (502) is arranged laterally of the middle drive wheel (501), and the middle drive wheel (501) is connected at the upper end to a first hydraulic rod (506); the inner drive wheel (601) is arranged at the lower end of the inner support (6), wherein the inner drive wheel is connected to a second drive motor (603), the inner support base (602) is arranged laterally of the inner drive wheel (601), and the inner drive wheel (601) is connected at the upper end to a second hydraulic rod (507); a rotating base (605) is arranged between the inner drive wheel (601) and the inner support (6), wherein the rotating base (605) is connected to a third drive motor (604). [5] Assembly device for prefabricated components of bridge deck systems according to claim 4, characterized by that a rotation axis (109) and an automatic latch (108) are arranged on each of the two sides of the outer column head support (105), the outer column head support (105) being connected to the foldable column head support (104) via the rotation axis (109), and the fixed portal (1) being articulated to the movable portal (101). [6] Assembly device for prefabricated components of bridge deck systems according to claim 5, characterized by that the length of the rails (103) is greater than the distance between the outer extendable support (4) and the inner support (6), wherein a limiting block (106) is arranged at the upper end of the outer column head support (105), and a guide plate (307) is arranged at the lower end of the first extendable frame (302). [7] Assembly device for prefabricated components of bridge deck systems according to claim 6, characterized by that a prefabricated component (8) is arranged beneath the mobile carriage (2), the prefabricated component (8) having a lifting hole on the side, the bolt (306) being guided through the bolt hole (305) and engaging in the lifting hole, the first extendable frame (302) resting on one side of the prefabricated component (8), and the second extendable frame (303) resting on the other side of the prefabricated component (8); a support (304) is arranged in the middle of the lower end of the lifting frame (3), the lower end of the support (304) resting on the upper side of the prefabricated component (8). [8] Assembly device for prefabricated components of bridge deck systems according to claim 7, characterized bythat prefabricated components already mounted are arranged on the bridge surface, wherein the prefabricated components already mounted are provided with an auxiliary laser sensor (7), wherein a first laser sensor (312) is arranged at the lower end of the support (304), and a second laser sensor (313) is arranged on the underside of the first extendable frame (302). [9] Assembly device for prefabricated components of bridge deck systems according to claim 8, characterized by that guide wheels (504) are arranged laterally on the central support (5), wherein the guide wheels (504) are arranged in pairs, and the guide wheels (504) rest on the side of the already assembled prefabricated components.

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