AUTOMATIC PROCESS FOR THE PRODUCTION OF REINFORCEMENT CAGES FOR TUNNEL SEGMENTS AND OPERATING LINE FOR IMPLEMENTING THE PROCESS

DETAILED DESCRIPTION

Field of the art

Tunnel castings or segments are arch-shaped panels made of reinforced concrete with which the walls of the road and railway tunnels are lined for the purpose of holding the rocks and the soils that define and interface the tunnel.

In the most modem embodiments, the tunnel segments are laid on site by the same machine, so-called “mole”, which digs the tunnel; in a second portion thereof, with respect to the excavation and advancement front, which immediately creates safety conditions just made and as it is progressively carried out. The prior art provides for the substantially manual production of tunnel segments, in the sense that the reinforcement cages, intended to be embedded in the cement casting moulds to form the finished article, are made manually by teams of assembling and welding workers.

This manual operation consists of an operative constriction at the speed of the drilling machine in the advancement and supply of segments for the immediate application to the rocky fronts just exposed by the excavation.

In any case, this manual operation is very expensive considering the amount of labour required.

What is believed to be the most commonly disclosed prior art regarding the object of the present invention is represented by CA1315533C, EP0308837B1, EP0631830B1, EP1733820A1, W02012101559A1, W02011001341A2,

EP2580008B1, US9896841B2, EP2190606A2, WO2015071277A1.

Objects of the invention

In this context, the main object of the present invention is to provide a method for the automatic production of tunnel segments. Another object of the present invention is to provide a production line for the active implementation of the method.

Yet another object of the present invention is to achieve the preceding objects by means of a method and a production line of relative embodiment which do not subvert the terms of production of tunnel segments according to the prior art.

Another object of the present invention is to achieve the preceding objects by means of a method and a production line of relative embodiment which allows to automatically produce tunnel segments with differentiated strengthening according to the greater or lesser pressure to be contained according to the characteristics of the drilled rocks and of each and any other variable need.

Still another object of the present invention is to achieve the preceding objects through a method and a production line for the relative implementation which allow implementation even in temporary plants near the openings of the tunnels to be made. A further object of the present invention is to attain the previous objects through a solution concept that is simple and efficient, safe in use and a relatively economic cost considering the results practically attainable therewith.

Summary of the solution concept

These and other objects are all achieved through the automatic method for the production of tunnel segments, according to the present invention as defined by the claims, comprising the steps of: vertically superimposing a plurality of curved steel bars 11 in at least one longitudinally vertical warp 11 of equally spaced superimposed parallel bars 11; welding orthogonal wefts 21 to the superimposed parallel bars 11 of the vertical warp 11 to form curved grids 31, wherein said orthogonal wefts 21 consist of straight steel bars 21 which are bent apically 22; pairing two curved grids 31 thus formed approached parallel mutually twinned in pairs 32; insertion between the meshes of the two paired grids 31 of a succession of arrays of crosspieces 51; and welding the crosspieces 51 to the curved grids 31. As well as an automatic means operating line for implementing the method, also according to the present invention as defined by the claims, comprising: supports 12 for vertically superimposing 13 and supplying a plurality of curved steel bars 11 in at least one longitudinally vertical warp 11 of equally spaced superimposed parallel bars 11; means for step-by-step advancement of the vertical warp 11 of parallel bars 11; means 24 for welding - in succession equally-spaced - to each of the superimposed parallel bars 11 of the longitudinally vertical warp 11 of orthogonal wefts 21 consisting of straight steel bars 21 bent with right angles in the same direction at the ends in parallel apical crosspieces 22 of homogeneous length, all oriented on the same side of the curved grid 31 thus forming and formed; means for pairing two symmetrical grids 31 thus formed on the abutment front of the side crosspieces approached parallel mutually twinned in pairs; means for horizontal orientation tilting on an arched tilting cradle 42 of the assembly 32 consisting of the two paired grids 31; means for the step-by-step advancement of the assembly consisting of the two paired grids 31; means 53 for the mutual welding of the side crosspieces 22 of the assembly 32 consisting of two paired grids 31; means 50 for the insertion and supply - between the meshes of the two paired grids 31 - of a succession of equally spaced arrays of crosspieces 51; means 55 for welding the crosspieces 51 to the lower grid 31 simultaneously with the insertion and means 56 for welding to the upper grid 31 at a subsequent advancement step until a complete three-dimensional lattice reinforcement 60 is obtained; translation means for embedding the reinforcement 60 completed in the concrete in the mould; means for electronic adjustment and control.

Description of the attached drawings Further characteristics and advantages of the automatic process for the production of tunnel segments and the production line for the relative implementation according to the present invention shall be more apparent from the following detailed description of a preferred but non-exclusive embodiment thereof, represented solely by way of non-limiting example with reference to the attached drawings, wherein: Figure 1 shows a lateral view of an operating line of devices for implementing the process according to the present invention;

Figure 2 shows a plan view of an operating line of devices for implementing the process according to the present invention; Figure 3 shows a lateral perspective view of a first device of the operating line for implementing the process according to the present invention;

Figure 4 shows a lateral perspective view of a second device of the operating line for implementing the process according to the present invention;

Figure 5 shows a detail of the device of the operating line for implementing the process according to the present invention;

Figure 6 shows a lateral perspective view of a fifth device of the operating line for implementing the process according to the present invention;

Figure 7 shows a detail of the fifth device of the operating line for implementing the process according to the present invention; Figure 8 shows another detail of the fifth device of the operating line for implementing the process according to the present invention;

Figure 9 shows a perspective view of the product of the operating line for implementing the process according to the present invention.

Static description of the embodiment With reference to the figures and in particular to figures 1 and 2, indicated with 10 is a first device of the operating line for implementing the process according to the present invention, production line to be understood as being entirely run and controlled by electronic logic, consisting of a double sorter- supplier 10 of curved warp bars 11 to a second device 20 of the operating line, consisting of two groups 20 of superimposed welding elements 24, said groups 20 of vertical welders 24 being twinned by fixing orthogonal weft bars 21 to the curved warp bars 11 so as to constitute shaped grates 31.

The shaped grids 31 in a third station 30 are oriented from a vertical operating posture to a horizontal operating posture and mutually complementarily counter-faced in pairs 32. By means of a movable bridge 40, the pairs 32 of grids 31 are translated on a tilting supply cradle 42 of a device 50 for dispensing crosspieces 51 and for welding them by means of horizontal welders 55 and 56 arranged side by side, from which, after possible addition of lateral reinforcement bars 52, they arrive on a tilting discharge cradle 61 to form the complete reinforcements 60.

In greater detail (see figure 3) the double sorter-supplier 10 provides two opposite orders of columns 12, with mutual positioning and orientation adjustable and adjusted in the two series as a function of the curvature of the curved warp bars 11, which they support superimposed on two parallel curved vertical planes by means of respective superimposed arms 13 with height- adjustable positioning.

The result is two curved warp bars 11 with a differentiated curvature as a function of parallel mutual complementarity, as better illustrated hereinafter.

Each of the two twinned vertical welders 20 comprises a plurality of superimposed movable arms 23 provided with an alternating pressure and step-by- step advancement synchronised movement of each of the curved warp bars 11, which - at each step - are stationed between respective electro-welding heads 24, which are opposite with reciprocating movement, suitably structured, supported, displaced and supplied to engage and disengage the operating line and carry out orthogonal welding of metal bars as better illustrated hereinafter. When in retracted position, between the welding heads 24 there also terminates the kinematic mechanism for supplying the straight weft bars 21, supplied orthogonal to the curved warp bars 11, picked up by a loader 25 for supplying a consecutive plurality thereof.

The straight weft bars 21 are bent orthogonally at the ends in apical crosspieces 22 with homogeneous length, all oriented on the same side of the curved warp bars 11 to which they are connected, while they are oriented opposite with reference to the two curved warp bars 11 with differentiated curvature which are formed in each of the two twinned vertical welders 20. The curved shaped grids 31 which exit from the two twinned vertical welders 20 (see figure 2 and figure 4) therefore carry arrays of side crosspieces 22 which protrude counter-faced in a juxtaposed fashion.

The reference numeral 30 is then used to indicate in its entirety a tilting station, wherein the curved shaped grids 31 which exit from the two twinned vertical welders 20, are twinned in pairs 32 with respective parallel curvature on the front of the respective side crosspieces 22, the latter therefore mutually space them by an amount equal to the respective homogeneous length or protrusion thereof.

Preferably automatic tilting means, such as for example robotic arms according to the prior art, therefore lay - in plan view - the pairs 32 of twinned grids 31 and - in this position - there may be trapped therebetween accessory means, such as metal spirals 33 to obtain reinforced holes in the finished product, as outlined hereinafter.

The reference numeral 40 is therefore used to indicate a movable bridge, slidable on tracks 41, suitable to pick up the two curved grids 31 mutually coupled interspaced and to transfer them on a tilting supply cradle 42 (in particular see figure 1 and figure 6) arch-shaped in complementarity of the curvature of the two twinned curved grids 31.

The tilting supply cradle 42 is inclined by translating foot linkages 43, motor-driven in a known manner, and it carries the two twinned curved grids 31 to the device 50 which dispenses crosspieces 51 and welders thereof through horizontal welders 55 and 56 arranged side by side, in which the two twinned curved grids 31 are retrieved through the inclination of the cradle 42 and then by the means for the step-by-step advancement of the assembly consisting of the two paired grids 31 actuated by lower drive means adjustable in the stroke of the straight weft bars 21 not illustrated.

The device 50 for dispensing crosspieces 51 and horizontal welder comprises two gripper-like electrowelders 53 for each side, suitable to engage and disengage the operating line and mutually weld - with subsequent steps - the side crosspieces 22 - arranged side by side - of the pairs 32 of twinned grids 31 on the two sides thereof.

The device 50 for dispensing crosspieces 51 and horizontal welder further comprises upper means 54 for supplying inserting crosspieces 51 with subsequent steps, in vertical coincidence of lower electrowelders 55, axially on which there are provided homologous upper electrowelders 56 with an advancement step of the pairs 32 of twinned grids 31 which are thus embedded in monolithic reinforcements 60.

The monolithic reinforcements 60 may be reinforced by arched lateral reinforcement bars 52 which are welded to the assembly by the lateral electrowelders 53 (see figure 8).

The monolithic reinforcements 60 exiting from the are received by the tilting discharge cradle 61 inclined by translating foot linkages 62 to adjust the orientation thereof to the gradual release of the arched reinforcements 60, from where the latter can be picked up to be arranged such as lattice on formworks for the purposes outlined hereinafter.

Dynamic description of the embodiment

Thus, having completed the static description of preferred embodiments of the automatic process for the production of tunnel segments and of the production line for the relative implementation according to the present invention, below is the dynamic description, or the relative operation, which in another approach corresponds to the process according to the invention: the mutual adjustment positioning - on the ground - of the columns 12, suitably anchored, and the height-adjustment of the relative superimposed arms 13, allow to easily adapt the production line, together with relative computerised logic servo mechanism connection to each and any required curvature in the reinforcements or lattices 60 consisting of the finished product and designed to reinforce the tunnel segments suitably embedded in a mould in appropriate concrete conglomerate. An embodiment of the reinforcements - in plan view - as disclosed by the prior art, mentioned in the dedicated chapter above, for the production of three- dimensional reticular structures is not suitable for the automatic production of arched reinforcements, due to the fact that the elements to be changed and the adjustments to be carried out as the shape of the curvature changes are too many and too complex, hence the concept according to the present invention to provide the components of the reinforcement vertically.

Therefore, according to the invention, once due adjustments are carried out in the positioning of the columns 12 and of the arms of the columns 13 as a function of the curvature of the bars 11, the process starts with the vertically superimposing of a plurality of curved steel bars 11 in two longitudinally vertical parallel warps 11 of superimposed and equally spaced parallel bars 11, to instantly form wefts 11.

The vertical wefts 11 of parallel bars 11 are therefore advanced step-by-step in and through the two groups 20 of superimposed welding elements 24, where there was carried out the equally spaced welding to each of the superimposed parallel bars 11 of the vertical warp 11 of orthogonal wefts 21 consisting of straight steel bars 21 bent with right angles in the same direction at the ends in parallel apical crosspieces 22 of homogeneous length, all oriented on the same side of the curved grid 31 thus forming and formed.

The two curved symmetrical grids 31 thus formed are then paired counter faced on the respective abutment front thereof of the side crosspieces 22, therefore obtaining the curved grids 31 approached parallel mutually twinned in pairs 32, which are tilted in horizontal orientation on the supply arched tilting cradle 42 of the welder 50 for dispensing crosspieces 51.

The arched tilting cradle 42 upon receiving the pairs 32 of curved grids 31 approached parallel mutually twinned inclines tilting upon the action of the arms 43 suitably motor-driven to feed - in a straight manner - the dispenser and welder 50 of crosspieces 51 compensating the arching thereof. In the dispenser and welder 50 of crosspieces 51 the pairs 32 of curved grids 31 approached parallel and mutually twinned pass through step-by-step, for example through a reciprocating motion advancement device which engages - with concealable drive means- the weft bars 21; in each step there intervenes: mutual welding of the side crosspieces 22 of the assembly 32 consisting of the two paired grids 31 ; insertion - between the meshes of the two paired grids 31 - of a succession of equally spaced arrays of crosspieces 51; welding the crosspieces 51 to the lower grid 31 simultaneously with the insertion and to the upper grid 31 at a subsequent advancement step until a complete three-dimensional reinforcement 60 is obtained.

The completed reinforcement 60 or lattice 60 will then be embedded in a concrete cast in the mould, according to the prior art. Alternative embodiments

It is obvious that in further alternative embodiments still falling within the innovation concept subject of the embodiment illustrated above and claimed below, the automatic process for the production of tunnel segments and the production line for the relative implementation according to the present invention, may be implemented through equivalent technical and mechanical solutions, i.e. provided with further supplementary solutions, just like - in the claimed scope - all elements they are made of may vary in a manner suitable for the purpose and adapted to the specific conformation and structure.

In particular: the means for inserting the crosspieces are two in the described and illustrated example, but they can be multiplied, together with relative lower and upper welders, to achieve the reinforcement of the final lattices.

In another approach, there may be conceived a plurality of means for inserting crosspieces, together with relative upper and lower welders, to be actuated partly or fully depending on the robustness of the lattice to be provided according to the needs, depending on the composition of the rock to be contained in the section of the tunnel that the segments are intended for.

Alternatively, there may be conceived devices for inserting crosspieces that are movable orthogonally with respect to the superimposed meshes, with equal mobility of the respective lower and upper welders; therefore, the multiplication of the crosspieces may be obtained by displacing operating means designated for the relative positioning and assembly, but to the detriment of production rate.

In the same context, the operating line is contingently modular and polyvalent for substantially any structuring of the lattice forming the finished product in terms of robustness, or the amount of assembled reinforcement; which is achieved very easily by increasing the number of curved warp bars superimposed to the supply and by decreasing the length of the advancement steps in the welders of the structure being formed, which translates into a multiplication of transverse warp bars as well as multiplication of the crosspieces. Advantages of the invention

As observable from the preceding detailed description of a preferred embodiment, the automatic process for the production of tunnel segments and the production line for the relative implementation according to the present invention, offer advantages corresponding to the attainment of these and other preset objects: as a matter fact it allows to obtain the possibility of automatically producing lattices or reinforcement cages of tunnel segments, in feasibility terms, which can also be carried out in loco, with polyvalence and modularity depending on the robustness contingently required of the finished article as a function of the intended use of lining rocks and soils - more or less self-supporting - after excavating.

KEY TO REFERENCE NUMBERS

10) curved bars sorter-supplier in its entirety

11) curved warp bars

12) columns 13) arms of the columns

20) vertical double welder in its entirety

21) orthogonal weft bars

22) apical crosspieces of the orthogonal weft bars

23) superimposed movable arms of the vertical welders 24) welding heads

25) loader supplier of the orthogonal weft bars

30) tilting station in its entirety

31) shaped grids

32) pairs of shaped grids 33) spirals

40) movable bridge in its entirety

41) tracks of the movable bridge

42) tilting supply cradle

43) inclination linkages of the tilting supply cradle 50) means for dispensing crosspieces and horizontal welder in its entirety

51) crosspieces

52) lateral reinforcement bars

53) lateral gripper- like electrowelders

54) means for supplying inserting crosspieces 55) lower electro welders

56) upper electrowelders

60) finished reinforcements in their entirety

61) discharge tilting

62) inclination linkages of the tilting discharge cradle