Double Production Line for Segmental Beam Prefabrication
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Solution Overview
Problem
The existing single-line production method for segmental beams in prefabricated bridge construction is inefficient, leading to delays in the bridge construction process.
Innovation Solution
A double production line system with two production machines and a track system, including a fixed end mold, side molds, a bottom mold trolley, and internal mold trolleys, allows for simultaneous pouring and demolding of segmental beams, with the end-formed beams serving as formwork for subsequent pours, enabling continuous and orderly removal and transport of beams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single line production method is used for segmental beams, then the production process is simple, but the production efficiency is low and delays bridge construction
Solution Approach 1:
The production system is divided into multiple independent production lines (double production line) that operate simultaneously. Each production line includes separate molds, trolleys, and forming systems, allowing parallel production of segmental beams without interfering with each other, thus doubling the production capacity.
Solution Approach 2:
The patent combines the pouring and demolding operations into a unified continuous process. The demolding area is integrated with the pouring area through the track system, allowing formed beams to be automatically transferred from one production line to storage while another line continues pouring, eliminating idle time and improving overall productivity.
2Loss of time
If traditional demolding and transport processes are used, then the process steps are clear, but the time consumption is high
Solution Approach 1:
The end formwork is designed to be reusable and is prepared in advance. After a beam is formed, the end formwork is removed and immediately prepared for the next pouring operation, while the formed beam itself serves as the end formwork for subsequent beams in the sequence, eliminating the need to manufacture new formwork each time and significantly reducing preparation time.
Solution Approach 2:
The track system enables continuous operation by allowing multiple trolleys to move simultaneously through different stages (pouring, demolding, storage) of the production process. While one trolley is being demolded, another is being poured, and a third is being transported, maintaining continuous productive action without idle periods.
3Productivity
If additional formwork is used for each pouring operation, then the forming quality is ensured, but the production cost and time increase
Solution Approach 1:
The end formwork is designed as a reusable component that is discarded from one position and recovered for use in the next position. After serving its function in closing the end opening of a pouring position, the end formwork (or the formed beam itself) is transferred and reused in subsequent pouring operations, eliminating the need for additional formwork materials and reducing both cost and preparation time.
Data Source
AI summary
The present application disclosures a double production line and a rapid prefabrication process of a segmental beam. The double production line including two production machine and a track system provided on the construction ground; the production machine includes a fixed end mold, two side molds, a bottom mold trolley, a middle internal mold trolley and two side internal mold trolley; two side molds are positioned on two sides of the fixed end mold respectively, the fixed end mold and two side molds together define a pouring position with an end opening, two openings of the pouring position are arranged facing each other; the track system includes a transverse track and a longitudinal track communicated with each other, two pouring positions are both positioned in the extension path of the transverse track, and the longitudinal track is positioned between two pouring positions.