CN115319911B - Digital production process of concrete prefabricated part with complex shape - Google Patents
Digital production process of concrete prefabricated part with complex shape Download PDFInfo
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- CN115319911B CN115319911B CN202210978715.9A CN202210978715A CN115319911B CN 115319911 B CN115319911 B CN 115319911B CN 202210978715 A CN202210978715 A CN 202210978715A CN 115319911 B CN115319911 B CN 115319911B
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- 239000004567 concrete Substances 0.000 title claims abstract description 74
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 31
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 168
- 239000010959 steel Substances 0.000 claims abstract description 168
- 230000002787 reinforcement Effects 0.000 claims abstract description 62
- 238000010276 construction Methods 0.000 claims abstract description 60
- 238000012545 processing Methods 0.000 claims abstract description 38
- 238000000034 method Methods 0.000 claims abstract description 34
- 238000009434 installation Methods 0.000 claims abstract description 25
- 238000005516 engineering process Methods 0.000 claims abstract description 22
- 238000013461 design Methods 0.000 claims abstract description 21
- 210000002435 tendon Anatomy 0.000 claims abstract description 15
- 230000013011 mating Effects 0.000 claims abstract description 13
- 239000000463 material Substances 0.000 claims description 32
- 239000002023 wood Substances 0.000 claims description 20
- 230000008520 organization Effects 0.000 claims description 13
- 238000001514 detection method Methods 0.000 claims description 9
- 238000003754 machining Methods 0.000 claims description 9
- 239000002002 slurry Substances 0.000 claims description 5
- 238000004873 anchoring Methods 0.000 claims description 3
- 239000004568 cement Substances 0.000 claims description 3
- 230000003203 everyday effect Effects 0.000 claims description 3
- 238000003780 insertion Methods 0.000 claims description 3
- 230000037431 insertion Effects 0.000 claims description 3
- 238000005192 partition Methods 0.000 claims description 3
- 239000011148 porous material Substances 0.000 claims description 3
- 238000005096 rolling process Methods 0.000 claims description 3
- 238000000638 solvent extraction Methods 0.000 claims description 3
- 230000003014 reinforcing effect Effects 0.000 description 7
- 238000005452 bending Methods 0.000 description 6
- 239000011513 prestressed concrete Substances 0.000 description 5
- 238000012360 testing method Methods 0.000 description 4
- 229910001294 Reinforcing steel Inorganic materials 0.000 description 2
- 238000012937 correction Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000007667 floating Methods 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 239000011178 precast concrete Substances 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 238000007599 discharging Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
Classifications
-
- 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
-
- 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
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
- E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
- E04C5/06—Reinforcing elements of metal, e.g. with non-structural coatings of high bending resistance, i.e. of essentially three-dimensional extent, e.g. lattice girders
- E04C5/0604—Prismatic or cylindrical reinforcement cages composed of longitudinal bars and open or closed stirrup rods
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
- E04C5/01—Reinforcing elements of metal, e.g. with non-structural coatings
- E04C5/06—Reinforcing elements of metal, e.g. with non-structural coatings of high bending resistance, i.e. of essentially three-dimensional extent, e.g. lattice girders
- E04C5/0636—Three-dimensional reinforcing mats composed of reinforcing elements laying in two or more parallel planes and connected by separate reinforcing parts
- E04C5/064—Three-dimensional reinforcing mats composed of reinforcing elements laying in two or more parallel planes and connected by separate reinforcing parts the reinforcing elements in each plane being formed by, or forming a, mat of longitunal and transverse bars
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
Abstract
The invention discloses a digital production process of a concrete prefabricated part with a complex shape, which comprises the following steps: s1, establishing a three-dimensional model of a mold; s2, generating a three-dimensional model of the reinforcement cage; s3, comprehensively planning the consumption of the steel bars and guiding out a steel bar blanking list; s4, forming a reinforcement cage processing technology intersection; s5, forming a mold assembly technology mating bottom; s6, forming a corrugated pipe and embedded part installation technology intersection; s7, repeatedly simulating a construction process flow; s8, processing the steel bars into a steel bar cage according to the S3 and the S4; s9, hanging in the machined reinforcement cage, and assembling all side plates of the die into a die according to the S5; s10, positioning the corrugated plate and the embedded part according to the S6 and rubbing the prestressed tendons; and S11, counting the volume of the component in software, leading out a concrete blanking list, and processing the component by adopting a post-tensioning method. The invention has lower professional quality requirements for constructors, shortens the design, production and installation periods of concrete prefabricated parts with complex shapes, and improves the working efficiency.
Description
Technical Field
The invention belongs to the technical field of concrete prefabricated part production, and particularly relates to a digital production process of a concrete prefabricated part with a complex shape.
Background
The building three-dimensional model is a tool applied to the building industry, and a three-dimensional model is built to scale building entities, so that people can conveniently study the relationship between the building entities and the surrounding environment, and a feasible scheme is made. In actual engineering construction, some building structures are complex and are difficult to express in a plan view and an elevation view, or constructors cannot understand the building structures correctly, so that the construction difficulty is caused. In order to enable constructors to correctly understand the intention of a designer and guarantee construction, a model is often adopted to display a complex structural part of a building so as to guide the construction.
In recent years, as the use of concrete prefabricated parts becomes more and more widespread, and the concrete prefabricated parts are being reduced in weight, the shape of the concrete prefabricated parts tends to be complex, and more severe requirements are put on the high performance, high precision and good appearance quality of the concrete prefabricated parts, so that the requirements of the concrete prefabricated parts with complex shapes from the aspects of design, deepening and production are very high. The quality of the concrete prefabricated part is affected by the selection of the mould, the production of the reinforcement cage and the positioning of the embedded part, and if errors exist in all links, the finally produced part can also generate larger errors and even needs to be produced again, so that the production cycle, the safety, the economy and the appearance of the engineering are greatly reduced.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a digital production process of a concrete prefabricated part with a complex shape, and aims to solve the problems that each link of the concrete prefabricated part with the complex shape is difficult to coordinate and match, accurate generation is realized and production efficiency is low.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
The invention provides a digital production process of a concrete prefabricated part with a complex shape, which comprises the following steps:
S1, obtaining the outline dimension of a concrete prefabricated part with a complex shape, establishing a three-dimensional model of a mould according to the dimension information of the part, and processing each side plate of the mould after determining the dimension of each side plate of the mould;
S2, carrying out steel bar arrangement design of complex nodes in modeling software, optimizing steel bar arrangement and end hook orientation aiming at complex nodes with more steel bars and limited space, and generating a three-dimensional model of the steel bar cage after collision detection is carried out in advance;
S3, according to the sizes and the number of the steel bars in the three-dimensional model of the steel bar cage, a steel bar blanking list is led out after the consumption of the steel bars is comprehensively calculated;
s4, optimizing the steel bar connection mode and the installation sequence according to the three-dimensional model of the steel bar cage, and then carrying out steel bar cage processing technology intersection;
s5, simulating a construction flow of lifting the reinforcement cage into the mould, and carrying out mould assembly construction technology mating after optimizing the assembly sequence of the templates;
S6, positioning the sizes and positions of the corrugated pipe and the embedded part in a three-dimensional model of the reinforcement cage, and carrying out collision detection in advance and then carrying out corrugated pipe and embedded part installation technology intersection;
s7, repeatedly simulating the construction process flow, and generating a construction organization plan after curve links are reduced;
S8, processing the steel bars into a steel bar cage according to the steps S3 and S4;
S9, hanging in the machined reinforcement cage, and assembling all side plates of the die into a die according to the step S5;
s10, positioning the corrugated pipe and the embedded part with high precision according to the step S6 and inserting prestress ribs;
And S11, counting the volume of the component in software, and processing the component by adopting a post-tensioning method after a concrete blanking list is derived.
Optionally, after obtaining the external dimension of the concrete prefabricated component with the complex shape, building a three-dimensional model of the mold according to the component dimension information, and processing each side plate of the mold after determining the dimension of each side plate of the mold comprises:
Firstly, building a three-dimensional model of a concrete prefabricated part with a complex shape, wherein the size of the three-dimensional model of the prefabricated part is consistent with that of an actual part; then, a three-dimensional model of the mould is established, a concrete prefabricated part three-dimensional model with a complex shape is placed in the three-dimensional model of the mould, the three-dimensional model and the concrete prefabricated part three-dimensional model are matched, whether the three-dimensional model of the mould is reasonable or not is determined, and then the mould materials, the sizes and the like of the mould are deepened;
the material of the mould is a rigid material or a wooden material. When the components are required to be produced in mass, the die can be made of rigid materials, the components are not easy to wear and damage during production and processing, and when the components are produced in small batches or only used as a test, the die can be made of wood materials, so that the assembly and the disassembly are convenient and flexible, and the cost is saved;
the internal mold size of the mold should be consistent with the size of the component, and the thickness of the mold depends on the material of the mold. If the mold material is a rigid material, the thickness is generally 8 mm-50 mm; if the die material is a wood material, the thickness is generally 10 mm-40 mm;
After the materials and the sizes of the die are determined, the digital production equipment can be utilized to carry out digital processing on each side plate of the die.
Optionally, the design of arranging the steel bars of complicated nodes is carried out in modeling software, and for the complicated nodes with more steel bars and limited space, optimizing the arrangement of the steel bars and the orientation of the end hooks, generating the three-dimensional model of the steel bar cage after the collision detection is carried out in advance comprises:
The method comprises the steps of obtaining the sizes, the numbers and the arrangement of concrete prefabricated member steel bars in complex shapes, inputting various parameters of the steel bars, arranging the steel bars, aiming at complex nodes with more steel bars and limited space, deepening the node structure of the steel bars, bending the tail ends of the steel bars by a certain angle and changing the bending direction, forming the steel bars into a whole, performing collision test, and generating a three-dimensional model of a final steel bar cage after no collision of the steel bars.
Optionally, according to the size and the number of the steel bars in the three-dimensional model of the steel bar cage, the step of guiding out the steel bar blanking list after the consumption of the steel bars is comprehensively calculated includes:
And the CAD graph is derived from the deepened three-dimensional model of the reinforcement cage, the dimension of the reinforcement can be marked on the CAD drawing, the reinforcement blanking table can be summarized by adopting reinforcement blanking software, and the reinforcement is digitally processed by adopting a reinforcement automatic processing instrument after the reinforcement blanking table is determined to be correct.
Optionally, optimizing the reinforcement connection mode and the installation sequence according to the three-dimensional model of the reinforcement cage and then performing reinforcement cage processing technology mating comprises:
The method is characterized in that the longitudinal stress steel bars, the transverse stress steel bars and the stirrups are integrated based on a three-dimensional model of the steel bar cage, the stress condition of the construction site construction environment and the concrete prefabricated member with a complex shape is combined, the connection mode of the steel bars is optimized, and the steel bar cage can be ensured not to deform and be damaged in moving and hanging by adopting binding connection, welding connection, mechanical connection or combined connection modes;
Optimizing the installation sequence of the steel bars based on the three-dimensional model of the steel bar cage, avoiding the collision between the transverse and longitudinal steel bar end bending parts and tightly combining the steel bars with the stirrups; and then the intersection of the reinforcement cage processing mode is carried out.
Optionally, the construction process of hanging the simulated reinforcement cage into the mould, and carrying out mould assembly construction technology mating after optimizing the template assembly sequence comprises the following steps:
Placing the reinforcement cage in a mould in software, adapting with the mould and optimally adjusting the assembly sequence of the templates; the template splicing preconditions are as follows: the steel bar cage is not collided when assembled; the splicing seam is not generated when the templates are spliced; avoiding the secondary assembly of the template, reducing the efficiency and the like. And (5) after confirming the splicing sequence of the templates, carrying out die splicing construction technology mating.
Optionally, positioning the size and the position of the corrugated pipe and the embedded part in the three-dimensional model of the reinforcement cage, and performing the mounting technology intersection of the corrugated pipe and the embedded part after performing collision inspection in advance includes:
Generating an embedded part three-dimensional model according to the three-dimensional model of the reinforcement cage, the size information and the arrangement position of the corrugated pipe and the embedded part, and establishing the premise that the corrugated pipe and the embedded part do not collide with the reinforcement; and after the detail drawing of the embedded part is generated, a CAD drawing can be derived, the drawing is marked with the dimension, and then the corrugated pipe and the embedded part are subjected to the installation technology intersection.
Optionally, repeatedly simulating the construction process flow, and generating the construction organization plan after reducing the curve links includes:
Repeatedly simulating a construction process flow, wherein the construction process comprises the following steps of: confirming the size of each side plate of the mould, machining each side plate of the mould, confirming a steel bar blanking table, machining steel bars, confirming the connection sequence and the installation sequence of the steel bars, machining a steel bar cage, hanging the steel bar cage to assemble with the mould, positioning a corrugated pipe and an embedded part, pouring concrete, curing, dismantling side forms, lifting the like in sequence;
According to the construction drawing, the construction days and the contract document, compiling construction organization design, partitioning the construction organization design according to preset sub-projects, and compiling a mating document for each sub-project of the partition; each sub project is constructed according to the intersection file, construction logs and data are written every day, and the construction logs and the data are checked with the organization design in the construction to confirm whether the correction is needed.
Optionally, processing the steel bar into the steel bar cage according to the steps S3 and S4 includes:
and (3) processing the digitally processed steel bars into a steel bar cage in an optimized connection mode and an optimized installation sequence, wherein the processed steel bar cage structure is consistent with the three-dimensional model of the steel bar cage in the step S2.
Optionally, hanging in the machined reinforcement cage and assembling each side plate of the die into the die according to the step S5 in sequence includes:
And (3) hanging the machined steel reinforcement cage on a bottom die of the die integrally, correcting the axis position after hanging in, and firmly positioning to avoid the phenomenon of floating cage when concrete is poured.
If the material of the die is rigid, splicing all side plates of the die into the whole die by a certain number of locating pins; if the material of the mould is wood material, lapping all side plates of the mould together, placing wood plates at certain intervals around the mould, wherein the height of the wood plates exceeds the height of the mould, the width is 50-80 mm, the thickness is 20-50 mm, finish rolling deformed steel bar counter-pulling side moulds are adopted above and below the wood plates, and all side moulds of the mould are assembled into the whole mould;
Optionally, positioning the bellows and the embedded part with high precision according to the step S6 and inserting the prestressed tendons includes:
Carrying out high-precision positioning and mounting on the corrugated pipe and other embedded parts according to the three-dimensional model of the embedded part and the CAD drawing; then inserting prestress ribs into the corrugated pipe, and after the insertion is finished, further adjusting the positions to enable the prestress ribs to be straight and parallel to each other so as to avoid twisting.
Optionally, the step of processing the component by using a pretensioning method or a post-tensioning method after counting the component volume and deriving the concrete blanking list in the software comprises the steps of:
Calculating the volume of the component in three-dimensional software, guiding out a concrete blanking list according to the design strength of the concrete, and processing the concrete prefabricated component by adopting a post-tensioning method;
And pouring concrete, tensioning the prestressed tendons in the corrugated pipes after the concrete strength of the components reaches the specified strength, anchoring the tensioned prestressed tendons at the end parts of the components by using an anchor, and finally pouring cement slurry into the pore canal to form the whole body of the prestressed tendons and the concrete components.
Compared with the prior art, the invention has the following technical effects: the invention adopts three-dimensional modeling software to establish information of components, molds, reinforcing steel bars, embedded parts and the like, wherein the three-dimensional model is consistent with the actual size, materials and construction environment of the components, the construction of each link is optimized according to the established three-dimensional model, and the digital production of the components is carried out after the construction of each link of the components is closely connected. The special quality requirements on constructors are low, the precision of manufacturing the concrete prefabricated parts is improved, the design, production and installation periods of the concrete prefabricated parts with complex shapes are shortened, and the working efficiency is improved.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic flow chart of a digital production process of a concrete prefabricated part with a complex shape according to an embodiment of the invention;
FIG. 2 is a schematic view of a complex-shaped concrete prefabricated part according to an embodiment of the present invention;
FIG. 3 is a schematic view of a wood mold for a complex-shaped concrete prefabricated part according to an embodiment of the present invention;
fig. 4 is a schematic diagram of the arrangement of the reinforcing steel bars at the nodes of the bottom and the side plates of the reinforcement cage model of the concrete prefabricated member with the complex shape according to the embodiment of the invention.
Wherein, the reference numerals specifically explain as follows: 1.2 and 3 are all side plates around the die; 4 is a support for supporting the upper mold; 5 is a cuboid plank upright post; 6 is screw steel; 7 is a gasket and a nut matched with the screw steel; 8 is a reserved bolt hole on the side die; 9 is a reserved corrugated pipe hole on the side die; 10 is the upper side plate of the mold; 11 is a component hole; 12 is a longitudinal stress steel bar at the bottom of the component; 13 is a transverse stress steel bar at the bottom of the component; 14. 15 is a member side beam longitudinal stress steel bar; and 16 is a member side beam stirrup.
Detailed Description
In the description of the present invention, it should be understood that the terms "longitudinal," "transverse," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like indicate orientations or positional relationships based on the orientation or positional relationships shown in the drawings, merely to facilitate describing the present invention and simplify the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and therefore should not be construed as limiting the present invention.
As shown in fig. 1, the embodiment provides a digitalized production process of a concrete prefabricated part with a complex shape, which comprises the following steps:
S1, obtaining the outline dimension of a concrete prefabricated part with a complex shape, establishing a three-dimensional model of a mould according to the dimension information of the part, and processing each side plate of the mould after determining the dimension of each side plate of the mould;
S2, carrying out steel bar arrangement design of complex nodes in modeling software, optimizing steel bar arrangement and end hook orientation aiming at complex nodes with more steel bars and limited space, and generating a three-dimensional model of the steel bar cage after collision detection is carried out in advance;
S3, according to the sizes and the number of the steel bars in the three-dimensional model of the steel bar cage, a steel bar blanking list is led out after the consumption of the steel bars is comprehensively calculated;
s4, optimizing the steel bar connection mode and the installation sequence according to the three-dimensional model of the steel bar cage, and then carrying out steel bar cage processing technology intersection;
s5, simulating a construction flow of lifting the reinforcement cage into the mould, and carrying out mould assembly construction technology mating after optimizing the assembly sequence of the templates;
S6, positioning the sizes and positions of the corrugated pipe and the embedded part in a three-dimensional model of the reinforcement cage, and carrying out collision detection in advance and then carrying out corrugated pipe and embedded part installation technology intersection;
s7, repeatedly simulating the construction process flow, and generating a construction organization plan after curve links are reduced;
S8, processing the steel bars into a steel bar cage according to the steps S3 and S4;
S9, hanging in the machined reinforcement cage, and assembling all side plates of the die into a die according to the step S5;
s10, positioning the corrugated pipe and the embedded part with high precision according to the step S6 and inserting prestress ribs;
And S11, counting the volume of the component in software, and processing the component by adopting a post-tensioning method after a concrete blanking list is derived.
Optionally, after obtaining the external dimension of the concrete prefabricated component with the complex shape, building a three-dimensional model of the mold according to the component dimension information, and processing each side plate of the mold after determining the dimension of each side plate of the mold comprises:
Firstly, building a three-dimensional model of a concrete prefabricated part with a complex shape, wherein the size of the three-dimensional model of the prefabricated part is consistent with that of an actual part; then, a three-dimensional model of the mould is established, a concrete prefabricated part three-dimensional model with a complex shape is placed in the three-dimensional model of the mould, the three-dimensional model and the concrete prefabricated part three-dimensional model are matched, whether the three-dimensional model of the mould is reasonable or not is determined, and then the mould materials, the sizes and the like of the mould are deepened;
the material of the mould is a rigid material or a wooden material. When the components are required to be produced in mass, the die can be made of rigid materials, the components are not easy to wear and damage during production and processing, and when the components are produced in small batches or only used as a test, the die can be made of wood materials, so that the assembly and the disassembly are convenient and flexible, and the cost is saved;
the internal mold size of the mold should be consistent with the size of the component, and the thickness of the mold depends on the material of the mold. If the mold material is a rigid material, the thickness is generally 8 mm-50 mm; if the die material is a wood material, the thickness is generally 10 mm-40 mm;
After the materials and the sizes of the die are determined, the digital production equipment can be utilized to carry out digital processing on each side plate of the die.
Optionally, the design of arranging the steel bars of complicated nodes is carried out in modeling software, and for the complicated nodes with more steel bars and limited space, optimizing the arrangement of the steel bars and the orientation of the end hooks, generating the three-dimensional model of the steel bar cage after the collision detection is carried out in advance comprises:
The method comprises the steps of obtaining the sizes, the numbers and the arrangement of concrete prefabricated member steel bars in complex shapes, inputting various parameters of the steel bars, arranging the steel bars, aiming at complex nodes with more steel bars and limited space, deepening the node structure of the steel bars, bending the tail ends of the steel bars by a certain angle and changing the bending direction, forming the steel bars into a whole, performing collision test, and generating a three-dimensional model of a final steel bar cage after no collision of the steel bars.
Optionally, according to the size and the number of the steel bars in the three-dimensional model of the steel bar cage, the step of guiding out the steel bar blanking list after the consumption of the steel bars is comprehensively calculated includes:
And the CAD graph is derived from the deepened three-dimensional model of the reinforcement cage, the dimension of the reinforcement can be marked on the CAD drawing, the reinforcement blanking table can be summarized by adopting reinforcement blanking software, and the reinforcement is digitally processed by adopting a reinforcement automatic processing instrument after the reinforcement blanking table is determined to be correct.
Optionally, optimizing the reinforcement connection mode and the installation sequence according to the three-dimensional model of the reinforcement cage and then performing reinforcement cage processing technology mating comprises:
The method is characterized in that the longitudinal stress steel bars, the transverse stress steel bars and the stirrups are integrated based on a three-dimensional model of the steel bar cage, the stress condition of the construction site construction environment and the concrete prefabricated member with a complex shape is combined, the connection mode of the steel bars is optimized, and the steel bar cage can be ensured not to deform and be damaged in moving and hanging by adopting binding connection, welding connection, mechanical connection or combined connection modes;
Optimizing the installation sequence of the steel bars based on the three-dimensional model of the steel bar cage, avoiding the collision between the transverse and longitudinal steel bar end bending parts and tightly combining the steel bars with the stirrups; and then the intersection of the reinforcement cage processing mode is carried out.
Optionally, the construction process of hanging the simulated reinforcement cage into the mould, and carrying out mould assembly construction technology mating after optimizing the template assembly sequence comprises the following steps:
Placing the reinforcement cage in a mould in software, adapting with the mould and optimally adjusting the assembly sequence of the templates; the template splicing preconditions are as follows: the steel bar cage is not collided when assembled; the splicing seam is not generated when the templates are spliced; avoiding the secondary assembly of the template, reducing the efficiency and the like. And (5) after confirming the splicing sequence of the templates, carrying out die splicing construction technology mating.
Optionally, positioning the size and the position of the corrugated pipe and the embedded part in the three-dimensional model of the reinforcement cage, and performing the mounting technology intersection of the corrugated pipe and the embedded part after performing collision inspection in advance includes:
Generating an embedded part three-dimensional model according to the three-dimensional model of the reinforcement cage, the size information and the arrangement position of the corrugated pipe and the embedded part, and establishing the premise that the corrugated pipe and the embedded part do not collide with the reinforcement; and after the detail drawing of the embedded part is generated, a CAD drawing can be derived, the drawing is marked with the dimension, and then the corrugated pipe and the embedded part are subjected to the installation technology intersection.
Optionally, repeatedly simulating the construction process flow, and generating the construction organization plan after reducing the curve links includes:
Repeatedly simulating a construction process flow, wherein the construction process comprises the following steps of: confirming the size of each side plate of the mould, machining each side plate of the mould, confirming a steel bar blanking table, machining steel bars, confirming the connection sequence and the installation sequence of the steel bars, machining a steel bar cage, hanging the steel bar cage to assemble with the mould, positioning a corrugated pipe and an embedded part, pouring concrete, curing, dismantling side forms, lifting the like in sequence;
According to the construction drawing, the construction days and the contract document, compiling construction organization design, partitioning the construction organization design according to preset sub-projects, and compiling a mating document for each sub-project of the partition; each sub project is constructed according to the intersection file, construction logs and data are written every day, and the construction logs and the data are checked with the organization design in the construction to confirm whether the correction is needed.
Optionally, processing the steel bar into the steel bar cage according to the steps S3 and S4 includes:
and (3) processing the digitally processed steel bars into a steel bar cage in an optimized connection mode and an optimized installation sequence, wherein the processed steel bar cage structure is consistent with the three-dimensional model of the steel bar cage in the step S2.
Optionally, hanging in the machined reinforcement cage and assembling each side plate of the die into the die according to the step S5 in sequence includes:
And (3) hanging the machined steel reinforcement cage on a bottom die of the die integrally, correcting the axis position after hanging in, and firmly positioning to avoid the phenomenon of floating cage when concrete is poured.
If the material of the die is rigid, splicing all side plates of the die into the whole die by a certain number of locating pins; if the material of the mould is wood material, lapping all side plates of the mould together, placing wood plates at certain intervals around the mould, wherein the height of the wood plates exceeds the height of the mould, the width is 50-80 mm, the thickness is 20-50 mm, finish rolling deformed steel bar counter-pulling side moulds are adopted above and below the wood plates, and all side moulds of the mould are assembled into the whole mould;
Optionally, positioning the bellows and the embedded part with high precision according to the step S6 and inserting the prestressed tendons includes:
Carrying out high-precision positioning and mounting on the corrugated pipe and other embedded parts according to the three-dimensional model of the embedded part and the CAD drawing; then inserting prestress ribs into the corrugated pipe, and after the insertion is finished, further adjusting the positions to enable the prestress ribs to be straight and parallel to each other so as to avoid twisting.
Optionally, the step of processing the component by using a pretensioning method or a post-tensioning method after counting the component volume and deriving the concrete blanking list in the software comprises the steps of:
Calculating the volume of the component in three-dimensional software, guiding out a concrete blanking list according to the design strength of the concrete, and processing the concrete prefabricated component by adopting a post-tensioning method;
And pouring concrete, tensioning the prestressed tendons in the corrugated pipes after the concrete strength of the components reaches the specified strength, anchoring the tensioned prestressed tendons at the end parts of the components by using an anchor, and finally pouring cement slurry into the pore canal to form the whole body of the prestressed tendons and the concrete components.
The embodiment also provides an actual application scene of the digital production process of the concrete precast element with the complex shape, which is used for producing a prestressed concrete containment element as shown in fig. 2, wherein the element comprises a bottom support, an upper side beam, a right side beam, a left side beam and a middle containment area; the left side beam and the right side beam are symmetrically arranged and have the same size, and reserved corrugated pipe holes are formed in the left side beam and the right side beam; the sizes of the upper side beam and the lower support are inconsistent, and bolt holes are formed in the upper side beam and the lower support; the central containment region has an opening and the containment region is not a plane. The member has a complex shape and internal reinforcement.
Firstly, the external dimension of the prestressed concrete containment component in fig. 2 is obtained, a three-dimensional model of the mould is built according to dimension information, and the dimension of each side plate of the mould is determined. In order to reduce the construction cost, the proposal adopts a wooden template to splice a wooden mould of the prestressed concrete containment component; in order to reduce construction difficulty, the containment component adopts transverse pouring, as shown in fig. 3, all the side plates 1,2 and 3 around the die and the side plate 10 at the upper part are cut to proper sizes by adopting wood plates, cuboid wood plate upright posts 5 are arranged around the side plates around the die in order to tightly connect the side plates around the die and ensure no slurry leakage, holes are formed above and below the cuboid wood plate upright posts, and the side plates 1,2 and 3 around the die are tightly connected by using screw steels 6 and matched gaskets and nuts 7; because the upper side beam and the lower support of the prestressed concrete containment component are respectively provided with bolt holes, the left side beam and the right side beam are respectively provided with reserved corrugated pipe holes, and a hole is reserved in the middle containment region, the bolt holes 8, the corrugated pipe holes 9 and the holes 11 are reserved in the corresponding region of the mould.
And (3) carrying out steel bar arrangement design in modeling software, optimizing steel bar arrangement and end hook orientation aiming at complex nodes with more steel bars and limited space, and generating a steel bar cage model after collision detection in advance. As shown in fig. 4, the arrangement schematic diagram of the node reinforcing bars at the bottom and the side plates of the prestressed concrete precast member reinforcement cage model is shown, at this time, the longitudinal stress reinforcing bars 12 at the bottom and the transverse stress reinforcing bars 13 of the member are welded, the longitudinal stress reinforcing bars 14 and 15 at the side beams of the member, the longitudinal stress reinforcing bars 12 at the bottom and the transverse stress reinforcing bars 13 of the member avoid collision and form a whole better, the hook orientations of the ends of the longitudinal stress reinforcing bars 14 and 15 of the side beams of the member are changed, and the whole reinforcement cage model is generated after all the nodes are arranged in this way.
According to the sizes and the quantity of the steel bars in the steel bar cage model, a steel bar blanking list is led out after the consumption of the steel bars is comprehensively calculated;
after the steel bars are processed, a steel bar connection mode is selected according to a steel bar cage model, the longitudinal stress steel bars 12 and the transverse stress steel bars 13 at the bottom of the component are welded, the longitudinal stress steel bars 14 and 15 of the side beams of the component are welded and bound with the longitudinal stress steel bars 12 and the transverse stress steel bars 13 at the bottom, and the longitudinal stress steel bars 14 and 15 of the side beams of the component are bound and connected with the stirrups 16 of the side beams of the component. Firstly, the longitudinal stress steel bars 12 and the transverse stress steel bars 13 at the bottom of the component are installed, then the longitudinal stress steel bars 14 and 15 of the side beam of the component, the longitudinal stress steel bars 12 and the transverse stress steel bars 13 at the bottom of the component are welded and bound together, and finally, the stirrups 16 of the side beam of the component are installed.
Hoisting the processed reinforcement cage into a station, sequentially splicing the side dies according to the templates in fig. 2, and fixing the deformed steel bars 6 on the side dies to ensure that slurry is not leaked during pouring; the corrugated pipe and the embedded part are bound and fixed on the steel reinforcement cage according to the drawing and inserted with the prestressed tendons, the component volume is counted in software, the concrete discharging list is led out, then the concrete is poured, and the prestressed tendons are fixed by the anchor device after 7 days.
In summary, the digital production process of the precast element of the embodiment improves the precision of manufacturing the precast concrete element, shortens the design, production and installation periods of the precast concrete element with complex shape, has simple flow and improves the working efficiency.
While the foregoing embodiments have been described in detail and with reference to the present invention, it will be apparent to one skilled in the art that modifications and improvements can be made based on the disclosure without departing from the spirit and scope of the invention.
Claims (4)
1. A digital production process of a concrete prefabricated part with a complex shape is characterized by comprising the following steps:
s1, obtaining outline dimension information of a concrete prefabricated part with a complex shape, establishing a three-dimensional model of a mold according to the obtained outline dimension information, determining the dimension information of each side plate of the mold, and processing each side plate of the mold;
S2, arranging the steel bars of the complex nodes in modeling software, determining the orientation of hooks at the ends of the steel bars, and generating a three-dimensional model of the steel bar cage after collision detection;
s3, according to the number and the size of the steel bars in the three-dimensional model of the steel bar cage, the consumption of the steel bars is comprehensively calculated, and a steel bar blanking list is derived;
S4, determining a steel bar connection mode and an installation sequence according to the three-dimensional model of the steel bar cage, and forming a steel bar cage processing technology intersection;
the method comprises the following steps: the method comprises the steps of integrating longitudinal stress steel bars, transverse stress steel bars and stirrups based on a three-dimensional model of a steel bar cage, and determining a connection mode of the steel bars by combining construction environment and stress of prefabricated components; determining the installation sequence of the steel bars based on the three-dimensional model of the steel bar cage;
S5, simulating a construction flow of lifting the reinforcement cage into the mould, determining the assembling sequence of the side plates, and forming a mould assembling technical mating bottom;
s6, determining the sizes and the positions of the corrugated pipe and the embedded part in the three-dimensional model of the reinforcement cage, and performing collision detection in advance to form a corrugated pipe and embedded part installation technology intersection;
The method comprises the following steps: generating an embedded part three-dimensional model according to the three-dimensional model of the reinforcement cage, the size information and the arrangement position of the corrugated pipe and the embedded part, deriving a CAD drawing after generating the embedded part three-dimensional model, marking the size on the drawing, and forming a corrugated pipe and embedded part installation technology intersection;
s7, repeatedly simulating a construction process flow;
The method comprises the following steps: confirming the size of each side plate of the mould, machining each side plate of the mould, confirming a steel bar blanking table, machining steel bars, confirming the connection sequence and the installation sequence of the steel bars, machining a steel bar cage, hanging the steel bar cage and the mould for assembly, positioning a corrugated pipe and an embedded part, pouring concrete, curing, and sequentially dismantling side moulds;
according to the construction drawing, the construction days and the contract document, compiling construction organization design, partitioning the construction organization design according to preset sub-projects, and compiling a mating document for each sub-project of the partition; each sub project is constructed according to the intersection file, construction logs and data are written every day, and the construction logs and the data are checked with the organization design in the construction to confirm whether the rectification is needed;
s8, processing the steel bars into a steel bar cage according to the S3 and the S4;
The method comprises the following steps: processing the digitally processed steel bars into a steel bar cage in an optimized connection mode and an optimized installation sequence, wherein the processed steel bar cage structure is consistent with the three-dimensional model of the steel bar cage in the step S2;
s9, hanging in the machined reinforcement cage, and assembling all side plates of the die into a die according to the S5;
The method comprises the following steps: hanging the machined reinforcement cage on a bottom die of a die integrally, correcting the axis position after hanging, and firmly positioning;
The mold is made of wood materials, all side plates of the mold are lapped together, wood plates are placed around the mold at certain intervals, the height of each wood plate exceeds the height of the mold, finish rolling deformed steel bar opposite-pulling side molds are adopted above and below each wood plate, and all side molds of the mold are assembled into the whole mold;
s10, positioning the corrugated plate and the embedded part according to the S6 and inserting the prestressed tendons;
S11, counting the volume of the components in software, leading out a concrete blanking list, and processing the components by adopting a post-tensioning method;
the method comprises the following steps: calculating the volume of the component in three-dimensional software, guiding out a concrete blanking list according to the design strength of the concrete, and processing the concrete prefabricated component by adopting a post-tensioning method;
And pouring concrete, tensioning the prestressed tendons in the corrugated pipes after the concrete strength of the components reaches the specified strength, anchoring the tensioned prestressed tendons at the end parts of the components by using an anchor, and finally pouring cement slurry into the pore canal to form the whole body of the prestressed tendons and the concrete components.
2. The digital production process of the complex-shaped concrete prefabricated part according to claim 1, wherein the step S1 is specifically as follows: firstly, building a three-dimensional model of a concrete prefabricated part with a complex shape, wherein the size of the three-dimensional model of the prefabricated part is consistent with that of an actual part, then building a three-dimensional model of a mould, placing the three-dimensional model of the prefabricated part into the three-dimensional model of the mould, adapting the three-dimensional model and the three-dimensional model, and carrying out digital processing on side plates of each mould by using digital production equipment.
3. The digital production process of the concrete prefabricated part with the complex shape according to claim 1, wherein the step S3 is specifically as follows: and (3) a CAD drawing is derived according to the three-dimensional model of the reinforcement cage, the reinforcement size is marked on the CAD drawing, a reinforcement blanking table is generated in a summarizing mode, and the reinforcement is digitally processed by adopting a reinforcement automatic production instrument.
4. The digital production process of the complex-shaped concrete prefabricated part according to claim 1, wherein the step S10 is specifically: carrying out high-precision positioning and installation on the corrugated pipe and the embedded part according to the three-dimensional model of the embedded part and the CAD drawing; then inserting prestress ribs into the corrugated pipe, and after the insertion is finished, further adjusting the positions to enable the prestress ribs to be straight and parallel to each other.
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