CLIMBING FORMWORK AND METHOD FOR ERECTION OF A CONCRETE STRUCTURE
20190145111 ยท 2019-05-16
Inventors
Cpc classification
E04G11/32
FIXED CONSTRUCTIONS
E04G17/002
FIXED CONSTRUCTIONS
G01C15/00
PHYSICS
E04G11/28
FIXED CONSTRUCTIONS
International classification
E04G11/28
FIXED CONSTRUCTIONS
E04G17/00
FIXED CONSTRUCTIONS
E04G11/32
FIXED CONSTRUCTIONS
Abstract
A climbing formwork and a method for erection of a concrete structure by successively casting a plurality of casting segments, the climbing formwork comprising a first form element for delimiting a cavity to receive concrete for forming an uppermost casting segment, the first form element having upper and lower ends, a support structure to support the first form element, a tilt sensor for measuring a tilt of the first form element, a measuring unit for measuring a horizontal distance between the lower end of the outer surface of the first form element and the upper end of the outer surface of the previous casting segment, a processing unit communicating with the tilt sensor and the measuring unit for calculating a target tilt of the first form element, the processing unit further for determining a deviation between the actual tilt and the target tilt of the first form element.
Claims
1. A climbing formwork for erection of a concrete structure by successively casting a plurality of casting segments, the climbing formwork comprising: at least a first form element with an outer surface for delimiting a cavity to receive concrete for forming an uppermost casting segment, the first form element having an upper end and a lower end, a first support structure to support the first form element, a first tilt sensor for measuring a tilt of the first form element, a first measuring unit for measuring a horizontal distance between the outer surface at the lower end of the first form element and an outer surface at an upper end of a previous casting segment, the outer surface at the upper end of the previous casting segment facing the outer surface of the first form element and a processing unit communicating with the first tilt sensor and the first measuring unit, the processing unit being arranged for calculating a target tilt of the first form element using the measurement of the horizontal distance between the lower end of the outer surface of the first form element and the upper end of the outer surface of the previous casting segment, the processing unit further being arranged for determining a deviation between an actual tilt and the target tilt of the first form element.
2. The climbing formwork according to claim 1, wherein the first measuring unit is arranged at the lower end of the first form element, wherein at least two first measuring units are arranged in a distance from one another in a horizontal direction transverse to a translational displacement of the first form element into a casting position.
3. The climbing formwork according to claim 1, wherein the first measuring unit comprises a wave transmitting and receiving device or a laser distance sensor.
4. The climbing formwork according to claim 1, wherein the first measuring unit comprises a contact element, moveable relative to the first form element from a first position into a second position when the first form element is moved into a casting position.
5. The climbing formwork according to claim 4, wherein the first measuring unit comprises a spring element which biases the contact element in a direction of the first position.
6. The climbing formwork according to claim 1, wherein the first measuring unit comprises a sensor housing having a front surface facing a cavity, the front surface being set back against the outer surface of the first form element.
7. The climbing formwork according to claim 1, wherein the first measuring unit comprises a first reference element arranged on the first support structure and a second reference element arranged on the first form element, the first measuring unit comprising an optical device, the optical device being arranged for locating the first reference element on the first support structure and the second reference element on the first form element respectively.
8. The climbing formwork according to claim 1, wherein the tilt sensor comprises a laser plummet device for emitting a vertical laser beam, a self-leveling support for mounting the laser radiation source thereon, a target plate for receiving the vertical laser beam from the laser radiation source and a camera unit for detecting a displacement of an intersection of the vertical laser beam with the target plate.
9. The climbing formwork according to claim 1, wherein the tilt sensor comprises a longitudinal element mounted on the first form element.
10. The climbing formwork according to claim 9, wherein the longitudinal element is connected to the first form element via a first pivoting support at the lower end of the first form element and a second pivoting support at the upper end of the first form element.
11. The climbing formwork according to claim 1, wherein the processing unit is connected to a data storage unit storing a correction value for a position of the first form element, the correction value being derived from a deviation between a position of the previous casting segment from a reference position of the previous casting segment, the processing unit being arranged for calculating the target tilt of the first form element using the correction value for the position of the first form element in addition to the horizontal distance between the lower end of the outer surface of the first form element and the upper end of the outer surface of the previous casting segment.
12. The climbing formwork according to claim 1, wherein the processing unit is connected to at least one of a displaying device for displaying the deviation between the target tilt and the actual tilt of the first form element, and a signaling device for signaling the deviation between the target tilt and the actual tilt of the first form element.
13. The climbing formwork according to claim 1, wherein a drive unit for adjusting the first form element relative to the first support structure, the drive unit comprising a first tilting unit for tilting the first form element and/or a first horizontal displacement unit for horizontally displacing the first form element and/or a first vertical displacement unit for vertically displacing the first form element.
14. The climbing formwork according to claim 13, wherein the processing unit is connected to the first tilting unit for tilting the first form element in accordance with the target tilt.
15. A method for erecting a concrete structure by successively casting a plurality of concrete segments, comprising the steps of: arranging a climbing formwork having at least a first form element with an outer surface in a casting position, wherein the first form element delimits a cavity to receive concrete for forming an uppermost casting segment, supporting the first form element in the casting position, measuring an actual tilt of the first form element, measuring a horizontal distance between a lower end of the outer surface of the first form element and an upper end of an outer surface of a previous casting segment, the outer surface of the upper end of the previous casting segment facing the outer surface of the first form element, calculating a target tilt of the first form element using the measurement of the horizontal distance between the lower end of the outer surface of the first form element and the upper end of the outer surface of the previous casting segment, and determining a deviation between the actual tilt and the target tilt of the first form element.
16. The climbing formwork according to claim 3, wherein the wave transmitting and receiving device is an ultrasonic wave transmitting and receiving device.
17. The climbing formwork according to claim 4, wherein the contact element is a pin.
18. The climbing formwork according to claim 7, wherein the first reference element is a first barcode element, wherein the second reference element is a second barcode element, and wherein the optical device is a camera.
19. The climbing formwork according to claim 8, wherein the laser plummet device comprises a laser radiation source.
20. The climbing formwork according to claim 9, wherein the longitudinal element is a measuring rod or a wire or a string, wherein the longitudinal element extends from the upper end of the first form element to the lower end of the first form element, and wherein the longitudinal element is connected to the first form element at the upper end and at the lower end of the first form element, respectively.
Description
[0066] In addition to the aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the figures and the following detailed description.
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[0084] In the shown embodiment, a crane may be used to lift the climbing formwork 1 after completion of a casting step. However, as is well known in the prior art, the first support structure 7 may be connected to a first lifting device and the second support structure 8 may be connected to a second lifting device. The first and second lifting device are arranged for lifting the first 4 and second form element 5 in a vertical direction from a first casting position for forming a first casting segment to a second casting position for forming a second casting segment, the second casting segment being arranged on top of the first casting segment. In this way, an automatic or self-climbing formwork is provided.
[0085] The climbing formwork 1 will be explained with reference to the first form element 4 and the first support structure 7 (as shown on the left-hand side of
[0086] The first support structure 7 comprises a support member 11, which is mounted on a drive unit 12 for adjusting the position and orientation of first form element 4 relative to the first support structure 7. In the shown embodiment, the drive unit 12 comprises a first tilting unit 13 for tilting the first form element 4. The tilting unit 13 permits the first form element 4 to be deployed in either of a vertical casting position (see
[0087] In the shown embodiment, the first support structure 7 comprises a working platform 7a for supporting the first form element 4 from below. However, in an alternative embodiment, the first form element 4 is suspended from the first support structure 7. Such suspending formworks are known in the prior art.
[0088] The drive unit 12 may comprise any known drives. For example, tilting unit 13 may include a hydraulic plunger and cylinder for tilting first form element 4. Furthermore, horizontal displacement unit 14 may include a carriage mechanism for horizontally displacing first form element 4, as explained in WO 2011/127970. In a less preferred embodiment, the form element 4 is manually adjusted for arrangement in the casting position.
[0089] In the casting position, the lower end of outer surface 4a of first form element 4 rests against the upper end of an outer surface 16a of the previous casting segment 16, i.e. the casting segment directly below the cavity 6 for forming the uppermost casting segment (see
[0090] In the shown embodiment, climbing formwork 1 comprises a first tilt sensor 15, also termed inclinometer, for measuring an inclination of the main plane of first form element 4 with respect to a vertical plane. The tilt sensor 15 may be of conventional design and is only schematically illustrated in the drawings. The climbing formwork 1 further comprises a first measuring unit 17 for measuring a horizontal displacement of the lower end of the first form element 4 with respect to a working platform 7a of first support structure 7. A processing unit 18 (see
[0091] The processing unit 18 calculates a target tilt of the first form element 4 based on the input from the first measuring unit 17, which measures the horizontal displacement of the lower end of the first form element (i.e. the end of the first form element 4 adjacent the working platform 7a). On this basis, the processing unit 18 determines a deviation between the actual tilt and the target tilt of the first form element 4.
[0092] For determining the horizontal position of the lower end of the first form element 4, the first measuring unit 17 comprises a first reference element 19 stationarily arranged on the first support structure 7 and a second reference element 20 arranged on the first form element 4. The first reference element 19 and the second reference element 20 are arranged in the field of view of an optical device 21 of the first measuring unit 15, as illustrated with dotted lines 22. Preferably, the optical device 21 is a camera capable of capturing images containing both the first reference element 19 and the second reference element 20. The processing unit 18 comprises an image processing unit 23 for determining a horizontal distance between a center point of the first reference element 19 and a center point of the second reference element 20. The first 19 and second reference element 20 preferably comprises a first and second barcode element, respectively. The second reference element 20 is arranged at the lower end of the first form element 4, while the first reference element 19 is arranged on the working platform 7a of first support structure 7. In the shown embodiment, the optical device 21 and the tilt sensor 15 are immovably attached to the first form element 4.
[0093] In preparation of the casting of the uppermost casting segment, the processing unit 18 compares the horizontal displacement of the second reference element 20 with respect to the first reference element 19 with the known horizontal distance between the outer surface 16a of the previous casting segment 16 and the first reference element 19. Based on this comparison, the processing unit 18 determines a gap, i.e. a horizontal distance, between the lower end of the outer surface 4a of the first form element 4 and the upper end of the outer surface 16a of the previous casting segment 16. Thus, it is checked whether the first formwork element 4 fully rests against the previous casting segment 16.
[0094] The processing unit 18 is further connected to a data storage unit 24 storing a multitude of correction values for the casting segment of the present casting step. The correction values for the casting segment are transformed into correction values for the position of the first form element 4 such that deviations of the previous casting segment 16 as built from the reference position as shown on the construction plan are compensated for in the present casting step. For the adjustment of the first form element 4, the processing unit 18 calculates the target tilt of the first form element 4 using the correction value for the position of the first form element 4 in addition to the measurement of the horizontal displacement of the lower end of the first form element 4.
[0095] As can be schematically seen from
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[0097] In this withdrawn position, the reinforcements 10 for the uppermost casting segment may be easily arranged. This is facilitated by a distance piece 28. In the shown embodiment, the distance piece 28 is pivotably mounted at the upper end of the first form element 4. In the withdrawn position of the first form element 4, the reinforcements 10 are brought in contact with the distance piece 28. In this case, it is ensured that the reinforcements 10 will be arranged in their intended position inside the cavity 6 after the distance piece 28 was removed and the first form element 4 moved into the casting position.
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[0099] At block 100, the measuring and adjustment procedure is started. At the outset, the climbing formwork 1 may run through a number of tests. At block 101, the power of the electronic components of the climbing formwork 1 is checked. At block 102, reference element 19 is located by means of first measuring unit 17. In the same fashion, reference element 20 is located at block 103. At block 104, the availability of a correction value for the present position of first form element 4 in data storage unit 24 is checked. At block 105, the information about the geometry, in particular the height, of the first form element 4 is verified. If any one of these checks fails, an error is returned at block 106. In this case, routines for eliminating the source of the error are followed (block 107), before the checks are repeated (block 108). If the checks at blocks 101 to 105 are completed successfully, the measurement of the horizontal displacement of the lower end of the first form element 4 is initiated (block 107). A control value is derived from the horizontal distance between the second reference element 20 and the first reference element 19 (block 108). The control value is compared to the known distance between the first reference element 19 and the outer surface 16a of the previous casting segment 16 (block 109). If this comparison results in a finding that the first form element 4 is in contact with the previous casting segment 16, the program proceeds to the calculation of the target tilt of the first form element 4 (block 110). If the control value indicates a displacement of the lower end of the first form element 4 from the a position of the first form element 4 resting against the previous casting segment 16, an error message is outputted at displaying device 25 (block 111). The operator may then decide whether the determined misalignment of the first form element 4 in the casting position is acceptable (block 112). If this is affirmed, the program proceeds to the calculation of the target tilt of the first form element 4 at block 110. On the other hand, if the deviation of the position of the first form element 4 exceeds a tolerable threshold, the program may return to step 107. At block 113, the tilt sensor 15 returns an actual tilt of the first form element 4. At block 114, the target tilt of the first form element 4 is compared to the actual tilt of the first form element 4. If the actual tilt of the first form element 4 corresponds to the target tilt, a message indicates the correct positioning of the first form element 4 (block 115) and the procedure is concluded (block 116). In case the actual tilt of the first form element 4 deviates from the target tilt, the displaying device 25 alerts the instructor of the deviation (block 117). The message may contain instructions how to manually adjust the inclination of the first form element 4 such that the target position of the upper end of the first form element 4 is achieved. At block 118, the tilt of the first form element 4 is adjusted manually or by means of the drive unit 12. The procedure then returns to the measurement of the horizontal displacement of the first form element 4 at block 107. This subroutine is repeated until the target tilt of the first form element 4 is achieved (block 114) so that the adjustment of the first form element 4 may be concluded (block 116).
[0100] Further embodiments of the invention are shown in
[0101] The embodiments of
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[0103] According to the embodiment of
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[0109] In the variants of
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[0112] In the embodiment shown in
[0113] The self-leveling support 62 may be connected to a dampening device for dampening vibrations of the self-leveling support 62 (not shown).