CN114888956A - Box girder production process - Google Patents
Box girder production process Download PDFInfo
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- CN114888956A CN114888956A CN202210502532.XA CN202210502532A CN114888956A CN 114888956 A CN114888956 A CN 114888956A CN 202210502532 A CN202210502532 A CN 202210502532A CN 114888956 A CN114888956 A CN 114888956A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 71
- 230000000712 assembly Effects 0.000 claims abstract description 31
- 238000000429 assembly Methods 0.000 claims abstract description 31
- 238000009415 formwork Methods 0.000 claims description 46
- 230000002787 reinforcement Effects 0.000 claims description 28
- 238000012423 maintenance Methods 0.000 claims description 20
- 239000004567 concrete Substances 0.000 claims description 14
- 238000013459 approach Methods 0.000 claims description 8
- 238000005266 casting Methods 0.000 claims description 8
- 229910000831 Steel Inorganic materials 0.000 claims description 6
- 238000007667 floating Methods 0.000 claims description 6
- 230000002265 prevention Effects 0.000 claims description 6
- 239000010959 steel Substances 0.000 claims description 6
- 230000006835 compression Effects 0.000 claims description 4
- 238000007906 compression Methods 0.000 claims description 4
- 230000009471 action Effects 0.000 claims description 3
- 238000000034 method Methods 0.000 abstract description 22
- 238000012546 transfer Methods 0.000 abstract description 15
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- 230000008569 process Effects 0.000 description 16
- 238000010586 diagram Methods 0.000 description 3
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- 238000011065 in-situ storage Methods 0.000 description 3
- 230000001360 synchronised effect Effects 0.000 description 3
- 238000004064 recycling Methods 0.000 description 2
- 239000011150 reinforced concrete Substances 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 229910001294 Reinforcing steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
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- 238000009417 prefabrication Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
- B28B23/04—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed
- B28B23/043—Wire anchoring or tensioning means for the reinforcements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/04—Discharging the shaped articles
- B28B13/06—Removing the shaped articles from moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
- B28B23/04—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed
- B28B23/06—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed for the production of elongated articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/16—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
- B28B7/18—Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/28—Cores; Mandrels
- B28B7/30—Cores; Mandrels adjustable, collapsible, or expanding
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- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Bridges Or Land Bridges (AREA)
Abstract
The invention discloses a box girder production process, and relates to the technical field of bridge engineering; the adopted technical scheme is as follows: the method comprises the following steps: a plurality of bottom die assemblies comprising a bottom die plate and a bottom die driver; the bottom die guide rail is used for supporting the bottom die assembly so as to drive the bottom die assembly to move along the length direction of the bottom die guide rail through the bottom die driver; the two-side die assembly comprises a side die plate and a side die driver, and the side die driver is used for driving the two-side die plate to be far away from or close to the bottom die plate; the two-end die assembly is detachably connected with the inner die assembly; the inner die assembly, the bottom die plate, the two side die plates and the two end die assemblies can enclose a box girder pouring die cavity. The invention can pour, maintain, stretch and transfer the box girder on a box girder production line, realize the production line type production of the box girder, also realize the uninterrupted use of the side mould assembly, the internal assembly and the end mould assembly, and improve the utilization rate of the box girder production mould, thereby improving the production efficiency of the box girder and ensuring the construction progress of the bridge.
Description
Technical Field
The invention relates to the technical field of bridge engineering, in particular to a box girder production process.
Background
The box girder is a girder with hollow interior and flanges at two sides of the upper part; the box girder combined bridge girder erection machine prefabricated in the independent site can be erected after the lower project is completed, the project progress can be accelerated, and the construction period can be saved, so that the prefabricated reinforced concrete box girder can be widely applied to modern bridge construction.
In the prior art, when a reinforced concrete box girder is prefabricated, a plurality of prefabricated box girder molds are arranged in a prefabrication workshop in parallel, after side molds and bottom molds are erected, a reinforcement cage is placed into a cavity of each prefabricated mold through hoisting equipment, and then an inner mold is erected inside the reinforcement cage for pouring; and after the concrete reaches the demolding strength, removing the inner mold and the side mold for subsequent maintenance and tensioning.
The inventor researches and discovers that in the prior art, when box girders are prefabricated, side molds and bottom molds are occupied before the box girders are transported to a transit car or a stock yard, the utilization rate of the molds is low, the production efficiency of the box girders is low, and the construction progress and the construction period of a bridge are influenced.
Disclosure of Invention
Aiming at the technical problem of low production efficiency caused by low utilization rate of the existing prefabricated box girder production mold; the invention provides a box girder production process which can improve the utilization rate of a box girder pouring mold, thereby improving the production efficiency of the box girder and ensuring the construction progress of a bridge.
The invention is realized by the following technical scheme:
a box girder production process comprises the following steps:
the side die drivers drive the two side die plates to approach the bottom die plate, and an inner die assembly and an end die assembly are erected so as to enclose a box girder pouring die cavity through the inner die assembly, the bottom die plate, the two side die plates and the two end die assemblies, wherein a box girder reinforcement cage is arranged in the box girder pouring die cavity;
pouring concrete into the box girder pouring die cavity;
after the concrete reaches the demolding strength, the end mold assembly and the inner mold assembly are disassembled, and the two side molds are driven by the side mold driver to be far away from the bottom template along the width direction of the bottom template, so that demolding is completed;
after demolding, driving the bottom template to move along the length direction of the bottom template through a bottom template driver so as to move the bottom template and the box girder blank on the bottom template out of a space between the two side templates;
and moving the other bottom template into the space between the two side templates, and repeating the steps to pour the next box girder.
The side die drivers drive the corresponding side die plates to approach the bottom die plate, and the die assemblies at two ends are respectively arranged at the corresponding end parts of the side die plates and the bottom die plate so as to enclose a box girder pouring die cavity through the bottom die plate, the two side die plates, the inner die assembly and the die assemblies at two ends, and box girder reinforcing steel bars are arranged in the box girder pouring die cavity; and injecting concrete into the box girder casting mold cavity through the concrete supply device so as to cast and form the box girder. And after the concrete reaches the demolding strength, removing the end mold assembly, the inner mold assembly and the two side templates to perform subsequent processes to complete the production of the box girder.
During demolding, the side die drivers drive the side die plates to be far away from the bottom die plate to realize demolding of the side die plates, and the bottom die drivers drive the bottom die plate to enable the bottom die plate supporting the poured box girder to move out of a space between the two side die plates, so that the box girder is maintained and tensioned on the bottom die plate after pouring; after the maintenance and tensioning operations are finished, the bottom die driver can drive the bottom die plate to move continuously in the direction away from the die plates on the two sides so as to convey the box girder to a transit workshop or a transit yard.
And after the box girder after the pouring is finished moves out of the space between the formworks on the two sides, the other bottom formwork can be moved into the space between the formworks on the two sides, and then the corresponding side formworks are driven by the side formwork drivers to be close to the bottom formwork, so that the space which is surrounded by the formworks on the two sides and the bottom formwork and is used for accommodating a steel reinforcement cage for producing the box girder is formed, and the box girder pouring operation is repeated.
In conclusion, the bottom template is driven to move, so that the pouring, maintenance, tensioning and transfer of the box girder can be realized on the same box girder production line, and the production line type production of the box girder is realized; meanwhile, only the bottom template is occupied on the whole production line, the bottom template can be repeatedly used, the side die assemblies, the inner assemblies and the end die assemblies can be continuously used, and the utilization rate of the box girder production die is improved. Therefore, the invention can improve the utilization rate of the box girder pouring mold, thereby improving the production efficiency of the box girder and ensuring the construction progress of the bridge.
In addition, in the prior art, a plurality of box girder molds are poured in parallel and maintained, tensioned and transported in situ, and a tensioning operation space and a transporting operation space need to be reserved at a pouring station; the invention realizes the production line type production of the box girder, and arranges the pouring process, the maintenance process, the tensioning process and the transfer process of the box girder production along the length direction of the bottom die guide rail, thereby ensuring that the pouring operation space, the tensioning operation space and the transfer operation space are distributed along the length direction of the bottom die guide rail, and reducing the floor area of the box girder production operation.
Specifically, the step of enclosing into the box girder pouring die cavity includes:
moving the bottom template to a position between the two side templates;
driving the two side formworks to approach the bottom formwork through a side formwork driver, and placing a bottom web plate reinforcement cage in a space enclosed by the bottom formwork and the two side formworks according to a set position;
connecting two lower end dies with the corresponding end parts of the bottom die plate and the side die plate;
moving the internal mold assembly into a through groove at the upper end of the bottom web plate reinforcement cage;
moving the top plate reinforcement cage to the upper end of the bottom web reinforcement cage to enclose the box girder reinforcement cage by the bottom web reinforcement cage and the top plate reinforcement cage;
and connecting the two upper end dies with the corresponding end parts of the bottom die plate and the side die plates, wherein the lower end dies and the upper end surfaces form an end die assembly, so that a box girder pouring die cavity is defined by the inner die assembly, the bottom die plate, the two side die plates and the two end die assemblies.
Further, the step of enclosing the box girder pouring mold cavity further comprises: the upper end of the box girder steel bar is provided with an upward floating prevention pressure lever, and the lower end of the upward floating prevention pressure lever is abutted against the upper end of the inner die assembly.
Further, the method also comprises the following steps: and driving the bottom die to move along the length direction of the bottom die through the bottom die driver, and conveying the box girder blank moved out from between the two side die plates to a maintenance station.
Further, the method also comprises the following steps: and driving the bottom die to move along the length direction of the bottom die through the bottom die driver, and conveying the box girder blank after the maintenance is finished to a tensioning station.
Further, the method also comprises the following steps:
lifting the box girder away from the bottom template after tensioning is finished;
and moving the bottom template lifted away from the box girder to a position between the two side templates.
Preferably, the bottom formwork is hung between the two side formworks through a travelling crane.
Specifically, the bottom die driver is erected on the bottom die guide rail, and the bottom die plate is driven to move along the length direction of the bottom die guide rail through the action of the bottom die driver.
Specifically, the end die assembly includes an upper end die plate and a lower end die plate that are detachably connected.
Preferably, when demoulding, the side die plate is driven by the demoulding driver to move along the width direction of the bottom die plate, and then the side die plate is driven by the side die driver to be far away from the bottom die plate.
The invention has the following beneficial effects:
1. the box girder production process provided by the invention is characterized in that a box girder pouring space is enclosed by a bottom template, two side templates, an inner mold assembly and two end mold assemblies, the bottom template is driven by a bottom template driver to move along the length direction of the bottom template, and the two side templates are driven by a side template driver to move away from or close to the bottom template; during demolding, the side die drivers drive the side die plates to be far away from the bottom die plate to realize demolding of the side die plates, and the bottom die drivers drive the bottom die plate to enable the bottom die plate supporting the poured box girder to move out of a space between the two side die plates, so that the box girder is maintained and tensioned on the bottom die plate after pouring is finished; after the maintenance and tensioning operations are completed, the bottom die driver can drive the bottom die plate to move continuously in the direction away from the die plates on the two sides so as to convey the box girder to a transfer workshop or a transfer yard, so that the pouring, maintenance, tensioning and transfer of the box girder can be realized on the same box girder production line, the production line type production of the box girder is realized, the production efficiency of the box girder is improved, and the construction progress of the bridge is ensured.
2. According to the box girder production process provided by the invention, after the box girder after pouring is moved out of the space between the two side formworks, the other bottom formwork can be moved into the space between the two side formworks, and then the corresponding side formworks are driven by the side formwork drivers to be close to the bottom formwork, so that the space which is enclosed by the two side formworks and the bottom formwork and is used for accommodating a steel reinforcement cage for producing the box girder is used for repeating the box girder pouring operation, the uninterrupted use of the side formwork assemblies, the internal assemblies and the end formwork assemblies can be realized, the utilization rate of the box girder production mold is improved, and the production efficiency of the box girder is further improved.
3. According to the box girder production process provided by the invention, a plurality of bottom mould assemblies are arranged at intervals along the length direction of a bottom mould guide rail, and a pouring process, a maintenance process, a tensioning process and a transfer process for box girder production are arranged along the length direction of the bottom mould guide rail, so that a pouring operation space, a tensioning operation space and a transfer operation space are distributed along the length direction of the bottom mould guide rail; in the prior art, a plurality of box girder molds are poured in parallel and maintained, tensioned and transported in situ, and a tensioning operation space and a transporting operation space need to be reserved at a pouring station; therefore, compared with the prior art, the invention can reduce the floor area of the box girder production operation.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are required to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained from the drawings without inventive effort.
FIG. 1 is a schematic structural diagram of a box girder production system in a front view after mold assembly according to an embodiment of the invention;
FIG. 2 is a schematic structural view of a box girder production system after demolding;
FIG. 3 is a schematic structural diagram of a bottom die assembly of the box girder production system according to the embodiment of the invention;
FIG. 4 is a schematic structural diagram of a side membrane module of a box girder production system according to an embodiment of the invention;
FIG. 5 is a schematic top view of a box girder production system according to an embodiment of the present invention;
fig. 6 is a flow chart of a production process of the box girder according to the embodiment of the invention.
Reference numerals: 100-bottom die assembly, 110-bottom die plate, 120-bottom die driver, 121-driving grooved wheel, 200-bottom die guide rail, 300-side die assembly, 310-side die plate, 320-side die driver, 330-side die guide rail, 340-side die support, 350-demolding driver, 400-traveling crane, 500-inner die assembly and 600-box girder pouring die cavity.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are some embodiments of the present application, but not all embodiments. The components of the embodiments of the present application, generally described and illustrated in the figures herein, can be arranged and designed in a wide variety of different configurations.
Thus, the following detailed description of the embodiments of the present application, presented in the accompanying drawings, is not intended to limit the scope of the claimed application, but is merely representative of selected embodiments of the application. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined or explained in subsequent figures.
In the description of the embodiments of the present application, the terms "central," "upper," "lower," "left," "right," "vertical," "longitudinal," "lateral," "horizontal," "inner," "outer," "front," "rear," "top," "bottom," and the like refer to orientations or positional relationships that are conventionally used in the manufacture of the present application, or that are routinely understood by those of ordinary skill in the art, but are merely used to facilitate the description and to simplify the description and do not indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore should not be considered limiting of the present application.
In the description of the present invention, unless otherwise expressly specified or limited, the terms "disposed," "open," "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict.
Examples
With reference to fig. 1 and fig. 2, in order to implement the box girder production process provided in this embodiment, the present embodiment provides a box girder production system. Wherein, the case roof beam production system that this embodiment provided includes: a plurality of bottom die assemblies 100, the bottom die assemblies 100 including a bottom die plate 110 and a bottom die driver 120; a bottom die guide rail 200, wherein the bottom die guide rail 200 is used for supporting a plurality of bottom die assemblies 100 so as to drive the bottom die assemblies 100 to move along the length direction of the bottom die guide rail 200 through the bottom die driver 120; the side die assemblies 300 comprise side die plates 310 and side die drivers 320, and the side die drivers 320 are used for driving the side die plates 310 to move away from or close to the bottom die plate 110; the inner die assembly 500, the inner die assembly 500 is used for supporting the middle cavity of the box girder; two end die assemblies detachably connected with the side die assembly 300; the inner mold assembly 500, the bottom mold plate 110, the two side mold plates 310 and the two end mold assemblies can enclose a box girder pouring mold cavity 600.
In detail with reference to fig. 3, the bottom die driver 120 includes a driving sheave 121, the driving sheave 121 is clamped on the bottom die guide rail 200, and the driving sheave 121 is rotated by a rotation driver, such as an electric motor or a hydraulic motor. The driving grooved pulley 121 is clamped on the bottom die guide rail 200, so that the bottom die assembly 100 can be lifted away from or onto the bottom die guide rail 200 through the lifting device while the bottom die plate 110 can move along the length direction of the bottom die guide rail 200 under the driving of the driver, thereby facilitating the recycling of the bottom die assembly 100.
Preferably, the length of the bottom die guide rail 200 is greater than three times of the length of the bottom die plate 110, and at least three bottom die guide rails 200 can be simultaneously arranged, so that the pouring, maintenance and tensioning of the box girder can be simultaneously realized. Typically, the length of the bed rail 200 is greater than five times the length of the bed plate 110 to increase the capacity of the maintenance station for the box beams and to facilitate removal of the box beams from the bed rail 200. It should be understood that in practical use, the bed die rails 200 are generally arranged in parallel two to ensure the smoothness of the movement of the bed die assembly 100 on the bed die rails 200.
Referring to fig. 5, the side mold assembly 300 further includes a side mold guide 330, and the side mold driver 320 is a linear driver; one end of the side die driver 320 is hinged to the side die guide rail 330, and the other end of the side die driver 320 is hinged to the side die plate 310, so that the side die plate 310 is driven by the side die driver 320 to move along the length direction of the side die guide rail 330. The linear driver is adopted to drive the side die plate 310 to move, the action is simple, the structure is simple, the control is simple, the structure and the control of the box girder production system can be simplified, and the reliability of the box girder production system is ensured. It will be appreciated that the linear actuator may be an electric push rod, a motor-driven lead screw slider mechanism, a pneumatic/hydraulic cylinder, etc., and in this embodiment, a hydraulic cylinder is used as the linear actuator.
Preferably, the side mold guide 330 is inclined along the length direction of the side mold guide 330, and one end of the side mold guide 330 facing the bottom mold plate 110 is higher than the other end of the side mold guide 330. When the side die drivers 320 drive the side die plates 310 to move, the side die plates 310 can be driven to move obliquely downwards along the length direction of the side die guide rails 330, and the top of the box girder is provided with side wings; therefore, the side mold rail 330 can be moved downward in an inclined direction to prevent the side mold plate 310 from damaging the side wings of the box girder during the mold release.
With continued reference to fig. 5, the side die assembly 300 further includes a side die support 340, the side die support 340 is slidably disposed on the side die guide rail 330, and the side die driver 320 is hinged to the side die support 340; the side die support 340 is provided with a demoulding driver 350, the side die plate 310 is arranged on one side of the side die support 340, and the demoulding driver 350 is used for driving the side die plate 310 to move along the width direction of the side die support 340. Before the side mold driver 320 drives the side mold plate 310 to move along the length direction of the side mold guide 330, the side mold driver 350 drives the side mold plate 310 to move along the width direction of the box girder so as to perform demolding, so that after the part of the box girder embedded in the side mold plate 310 is completely removed from the side mold plate 310, the side mold plate 310 is driven by the side mold driver 320 to move obliquely downwards, and the side mold plate 310 is further prevented from damaging the side wall of the box girder during demolding.
Preferably, the side die driver 320 and the demolding driver 350 are provided with displacement sensors. The displacement sensors are arranged on the side die driver 320 and the demoulding driver 350, so that the displacement of the moving ends of the side die driver 320 and the demoulding driver 350 can be monitored in real time, the position of the side die plate 310 relative to the side die guide rail can be monitored in real time, and the synchronous die closing or synchronous demoulding of the side die plate 310 can be conveniently realized. The two side templates 310 are synchronously matched, so that the phenomenon that the two side templates 310 are asynchronous when matched is avoided, the side template 310 firstly abutted against the bottom template 110 pushes the bottom template 110 to be in an inclined state, and the pouring forming quality of the box girder is further ensured. Synchronous drawing of patterns of both sides template 310 can make the side bolster 310 effect remove in step at the holding power of the corresponding lateral wall of case roof beam, avoids the case roof beam to rock at the drawing of patterns in-process.
It will be appreciated that the end form assembly includes an upper end form and a lower end form that are removably connected. The end mold of the box girder pouring mold cavity 600 is formed by the upper end mold and the lower end mold, so that the inner mold assembly 500 can be conveniently inserted and detached.
In order to further improve the production efficiency of the box girder, referring to fig. 5, the bottom die assembly 100 is provided in parallel with a plurality of rows to simultaneously produce the plurality of rows of box girders. Correspondingly, the bottom die guide rail 200, the side die assembly 300, the inner die assembly 500 and the end die assembly are correspondingly provided with a plurality of groups.
It should be noted that, this embodiment further includes a traveling crane 400, and the length direction of the guide rail of the traveling crane 400 is parallel to the length direction of the bottom mold guide rail 200. A travelling crane 400 capable of moving along the length direction of the bottom die guide rail 200 is arranged, so that the box girder is conveniently lifted from the bottom die plate 110 to realize quick transfer of the box girder; on the other hand, the used bottom formwork 110 is conveniently hung between the two side formworks 310, so that the bottom formwork 110 is quickly recycled, and the production efficiency of the box girder is ensured.
With reference to fig. 6, the process for producing a box girder provided by this embodiment includes the following steps:
s1, driving the two side templates 310 to approach the bottom template 110 through the side template driver 320, and erecting the inner template assembly 500 and the end template assembly so as to enclose a box girder pouring mold cavity 600 through the inner template assembly 500, the bottom template 110, the two side templates 310 and the two end template assembly, wherein a box girder reinforcement cage is arranged in the box girder pouring mold cavity 600.
The step of enclosing the box girder casting mold cavity 600 includes steps S11-S17, which are as follows:
s11, moving the bottom mold plate 110 between the two side mold plates 310 by the crane 400;
s12, driving the two side templates 310 to approach the bottom template 110 through the side template driver 320 and the demolding driver 350, then cleaning the bottom template 110 and the side templates 310, spraying a demolding agent on the surfaces of the bottom template 110 and the side templates 310, and placing a bottom web reinforcing cage in a space surrounded by the bottom template 110 and the two side templates 310 according to a set position;
s13, connecting two lower end dies with the corresponding ends of the bottom die plate 110 and the side die plates 310;
s14, assembling the inner mold assembly 500, and moving the inner mold assembly 500 into a through groove at the upper end of the bottom web plate reinforcement cage;
s15, moving the top plate reinforcement cage to the upper end of the bottom web reinforcement cage to enclose the box girder reinforcement cage through the bottom web reinforcement cage and the top plate reinforcement cage;
and S16, connecting two upper end dies with the corresponding end parts of the bottom die plate 110 and the side die plates 310, wherein the lower end dies and the upper end surfaces form end die assemblies, so that the box girder pouring die cavity 600 is surrounded by the inner die assembly 500, the bottom die plate 110, the two side die plates 310 and the two end die assemblies.
And S17, installing an upward floating prevention compression bar at the upper end of the box girder steel bar, wherein the lower end of the upward floating prevention compression bar props against the upper end of the internal mold assembly 500.
And S2, hoisting the concrete hopper through the pump truck or the travelling crane 400, and pouring concrete into the box girder pouring mold cavity 600.
And S3, after the concrete reaches the demolding strength, detaching the end mold assembly and the inner mold assembly 500, driving the two side molds to be far away from the bottom template 110 along the width direction of the bottom template 110 through the side mold driver 320, and completing demolding.
When demolding is performed, the side mold plates 310 are driven by the demolding drivers 350 to move along the width direction of the bottom mold plate 110, and then the side mold drivers 320 drive the side mold plates 310 to be away from the bottom mold plate 110.
S4, after demolding, the bottom mold plate 110 is driven by the bottom mold driver 120 to move along the length direction of the bottom mold plate 110, so as to move the bottom mold plate 110 and the box girder blank on the bottom mold plate 110 out of the space between the two side mold plates 310.
It should be understood that the subsequent processes after demolding include maintenance, tension, beam lifting, pressure drop and anchor sealing, and in this embodiment, the method further includes steps S41-S43, specifically:
and S41, driving the bottom die to move along the length direction of the bottom die through the bottom die driver 120, and conveying the box girder blank moved out from between the two side die plates 310 to a maintenance station.
And S42, driving the bottom die to move along the length direction of the bottom die through the bottom die driver 120, and conveying the box girder blank after the maintenance is finished to a tensioning station.
And S43, lifting the tensioned box girder away from the bottom template 110 to lift the tensioned box girder to a transfer yard, so that the box girder is subjected to grouting and anchor sealing operation to obtain a finished box girder.
And S5, moving the other bottom template 110 into the space between the two side templates 310, and repeating the steps to pour the next box girder.
The bottom template 110 lifted away from the box girder is lifted between the two side templates 310 by the crane 400, and the above steps are repeated, so that the recycling of the bottom template 110 can be realized.
In this embodiment, the side die drivers 320 drive the corresponding side die plates 310 to approach the bottom die plate 110, and the die assemblies at the two ends are respectively mounted at the corresponding ends of the side die plates 310 and the bottom die plate 110, so that the bottom die plate 110, the side die plates 310, the inner die assembly 500 and the die assemblies at the two ends enclose a box girder casting die cavity 600, and a box girder steel bar is arranged in the box girder casting die cavity 600; the box girder casting mold 600 is filled with concrete by a concrete supplying device to cast form the box girder. And after the concrete reaches the demolding strength, removing the end mold assembly, the inner mold assembly 500 and the two side templates 310 so as to perform subsequent maintenance and tensioning processes to complete the production of the box girder.
During demolding, the side die drivers 320 drive the side die plates 310 to be far away from the bottom die plate 110 to achieve demolding of the side die plates 310, and the bottom die drivers 120 drive the bottom die plate 110 to enable the bottom die plate 110 supporting the box girder after pouring to move out of a space between the two side die plates 310, so that the box girder is maintained and tensioned on the bottom die plate 110 after pouring is completed; after the maintenance and tensioning operations are completed, the bottom die plate 110 is driven by the bottom die driver 120 to move further away from the two side die plates 310, so as to deliver the box girder to a transfer workshop or a transfer yard.
After the box girder is poured out of the space between the two side formworks 310, the other bottom formwork 110 is moved into the space between the two side formworks 310, and the corresponding side formworks 310 are driven by the side formwork drivers 320 to be close to the bottom formwork 110, so that the space for accommodating a reinforcement cage for producing the box girder, which is surrounded by the two side formworks 310 and the bottom formwork 110, is repeated.
To sum up, in this embodiment, by driving the bottom mold plate 110 to move, the pouring, maintenance, tensioning and transferring of the box girder can be realized on the same box girder production line, so as to realize the production line type production of the box girder; meanwhile, only the bottom template 110 is occupied on the whole production line, and the bottom template 110 can be reused, so that the side die assemblies 300, the internal assemblies and the end die assemblies can be used uninterruptedly, and the utilization rate of the box girder production die is improved. Therefore, this embodiment can improve the utilization ratio of box girder casting die to improve the production efficiency of box girder, in order to ensure the construction progress of bridge.
In addition, in the prior art, a plurality of box girder molds are poured in parallel and maintained, tensioned and transported in situ, and a tensioning operation space and a transporting operation space need to be reserved at a pouring station; in this embodiment, the production line of the box girder is implemented, and the pouring process, the maintenance process, the tensioning process and the transfer process in the production of the box girder are arranged along the length direction of the bottom die guide rail 200, so that the pouring operation space, the tensioning operation space and the transfer operation space are distributed along the length direction of the bottom die guide rail 200, and the floor area of the production operation of the box girder can be reduced. The foregoing is only a preferred embodiment of the present invention, and the present invention is not limited thereto in any way, and any simple modification, equivalent replacement and improvement made to the above embodiment within the spirit and principle of the present invention still fall within the protection scope of the present invention.
Claims (10)
1. The box girder production process is characterized by comprising the following steps:
the side die drivers (320) are used for driving the die plates (310) on the two sides to approach the bottom die plate (110), the inner die assembly (500) and the end die assembly are erected, so that a box girder pouring die cavity (600) is defined by the inner die assembly (500), the bottom die plate (110), the two side die plates (310) and the two end die assembly, and a box girder reinforcement cage is arranged in the box girder pouring die cavity (600);
pouring concrete into the box girder pouring mold cavity (600);
after the concrete reaches the demolding strength, the end mold assembly and the inner mold assembly (500) are disassembled, the two side molds are driven by the side mold driver (320) to be far away from the bottom mold plate (110) along the width direction of the bottom mold plate (110), and demolding is finished;
after demolding, driving the bottom die plate (110) to move along the length direction of the bottom die plate (110) through a bottom die driver (120) so as to move the bottom die plate (110) and the box girder blank on the bottom die plate (110) out of a space between the two side die plates (310);
and moving the other bottom template (110) into the space between the two side templates (310), and repeating the steps to pour the next box girder.
2. A box girder production process according to claim 1, wherein the step of enclosing the box girder casting mold cavity (600) comprises:
moving the bottom form (110) between the two sideforms (310);
the two side templates (310) are driven by a side template driver (320) to approach the bottom template (110), and a bottom web plate reinforcement cage is placed in a space surrounded by the bottom template (110) and the two side templates (310) according to a set position;
connecting two lower end dies with corresponding ends of the bottom die plate (110) and the side die plates (310);
moving the inner die assembly (500) into a through slot at the upper end of the bottom web reinforcement cage;
moving the top plate reinforcement cage to the upper end of the bottom web reinforcement cage to enclose the box girder reinforcement cage by the bottom web reinforcement cage and the top plate reinforcement cage;
and connecting the two upper end dies with the corresponding end parts of the bottom template (110) and the side templates (310), wherein the lower end dies and the upper end surfaces form end die assemblies, so that a box girder pouring die cavity (600) is defined by the inner die assembly (500), the bottom template (110), the two side templates (310) and the two end die assemblies.
3. A box girder production process according to claim 2, wherein the step of enclosing the box girder casting mold cavity (600) further comprises: the upper end of the box girder steel bar is provided with an upward floating prevention compression bar, and the lower end of the upward floating prevention compression bar is abutted against the upper end of the inner die assembly (500).
4. A box girder production process according to claim 2, further comprising the steps of: the bottom die driver (120) drives the bottom die to move along the length direction of the bottom die, and the box girder blank moved out from between the two side die plates (310) is conveyed to a maintenance station.
5. The box girder production process according to claim 4, further comprising the steps of: the bottom die driver (120) drives the bottom die to move along the length direction of the bottom die, and the box girder blank after the maintenance is finished is conveyed to a tensioning station.
6. The box girder production process according to claim 5, further comprising the steps of:
lifting the tensioned box girder away from the bottom template (110);
and moving the bottom formwork (110) lifted off the box girder to a position between the two side formworks (310).
7. A box girder production process according to claim 6, wherein the bottom formworks (110) are suspended between the two side formworks (310) by means of a crane (400).
8. The box girder production process according to any one of claims 2 to 7, wherein the bottom die drive (120) is mounted on a bottom die rail (200), and the bottom die plate (110) is driven to move along the length direction of the bottom die rail (200) by the action of the bottom die drive (120).
9. A box girder production process according to claim 1 wherein the end form assemblies include upper and lower end forms which are detachably connected.
10. The box girder production process according to claim 1, wherein the side formworks (310) are driven to move in the width direction of the bottom formwork (110) by the side formwork drivers (350) and then the side formworks (310) are driven to move away from the bottom formwork (110) by the side formwork drivers (320) when demoulding.
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| CN202210502532.XA CN114888956A (en) | 2022-05-10 | 2022-05-10 | Box girder production process |
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