Patent Application
20230220774
The invention relates to a modular tunnel formwork device for concrete lining of tunnel walls.
Until now, the concrete lining of tunnel walls has been carried out by tunnel formwork fixtures that have to be erected and dismantled on site. The erection and dismantling of the device is carried out individually at each construction site and takes considerable time, which significantly increases the overall cost of a tunnel project.
It is therefore the task of the invention to create a tunnel formwork device that enables faster assembly and disassembly and also easier transport of the tunnel formwork device between different construction sites.
This task is solved by a modular tunnel formwork device including at least two modules, which are arranged one behind the other in a longitudinal direction of the tunnel formwork device and can be detachably connected to one another. The at least two modules each have a frame part, and the frame parts of the at least two modules form a frame of the tunnel formwork device. The modular tunnel formwork device also includes at least two support structures, which can be connected to the frame of the tunnel formwork device and are spaced apart from one another in the longitudinal direction of the tunnel formwork device, for supporting the frame on a tunnel floor. The frame carries at least two support struts, particularly support cylinders in at least two mutually spaced positions in the longitudinal direction. The support cylinders can be connected to longitudinal beams extending in the longitudinal direction. The longitudinal beams carry tunnel formwork elements of the tunnel formwork device.
The task is further solved by a mobile formwork arrangement including the modular tunnel formwork device and at least three transport vehicles for receiving the modules and supporting structures. The transport vehicles are formed in particular by an articulated truck or an articulated trailer of a freight train.
The task is also solved by a tunnel concreting device including the modular tunnel formwork device and at least one concrete pump which is controlled by the control arrangement for controlling the support cylinders of the tunnel concreting device. The tunnel concreting device also includes at least one delivery line of the concrete pump connected to an intermediate space between the tunnel formwork elements and a tunnel wall. The concrete pumps are preferably controllable in dependence on signals from load sensors arranged in connection with the support cylinders.
Advantageous further embodiments of the invention are also disclosed in the description and in the figures.
According to the invention, the tunnel formwork device has a modular structure and comprises at least two modules which are arranged one behind the other in the longitudinal direction of the tunnel formwork device and can be detachably connected to one another, the at least two modules each having a frame part, and the frame parts of the interconnected modules forming a frame of the tunnel formwork device. In addition, the tunnel formwork device has at least two support structures, which can be connected to its frame and are spaced apart from one another in the longitudinal direction of the tunnel formwork arrangement, for supporting the frame on a tunnel floor. These support structures are preferably arranged on the outer frame parts spaced apart from each other in the longitudinal direction, so that the frame is securely supported at its longitudinal ends by the support structures on the tunnel floor.
In addition, at at least two positions spaced apart from one another in the longitudinal direction, the frame carries at least two support cylinders or support struts in each case, which are preferably designed at least in part as hydraulically length-adjustable support cylinders that can be connected to longitudinal beams of the tunnel formwork device running in the longitudinal direction. These in turn carry tunnel formwork elements of the tunnel formwork device, which form the tunnel formwork.
According to the invention, a tunnel formwork device is thus formed by at least two modules, preferably by at least three modules connected to each other in the longitudinal direction of the tunnel formwork device, the length of which can be adjusted by the number of modules used. This has the advantage that the length of the tunnel formwork device can be individually adjusted as desired by the number of intermediate modules selected. It should be noted that the longitudinal direction of the tunnel formwork device coincides with the tunnel direction.
Optionally, the width of each module can be varied, for example by adapter pieces or by a hydraulic adjusting mechanism, so that not only the length of the tunnel formwork device in the longitudinal direction of the tunnel, but also the width of the tunnel formwork device can be adjusted according to the width of the modules. The working width of the modules can also be varied simply by adjusting the support structures and the length-adjustable hydraulic support cylinders accordingly so that both narrow and wide tunnel shapes can be formed. The tunnel shape is thereby adjusted by a corresponding adjustment of the length of the support cylinders, which are preferably hydraulic telescopic cylinders. By appropriately varying the standing width of the support structures, which are preferably adjustable both in their spacing in the transverse direction as well as in their height, adapted stability can be achieved even for wide tunnels. The vertical support cylinders do not have to be hydraulically adjustable in length, since the height adjustment of the tunnel formwork device can also be realized via the support structures.
Due to the fact that the entire tunnel formwork device is of modular design, it can be transported comparatively easily, i.e. by common transport vehicles, such as semitrailer trucks or semi-trailers of freight trains. For example, if the length of a module in the tunnel direction is between 1 and 4 m and the width is between 3 m and 10 m, conventional semitrailer trucks can be used to transport the modules because official maximum width and length regulations for transports via railway and on streets need not be exceeded.
Preferably, the modules comprise two end modules, which form the two ends of the tunnel formwork device in the longitudinal direction, and at least one intermediate module to be arranged between the end modules, which can be positively and/or non-positively connected to at least one of the two end modules. The end modules can thus be designed specifically for the load-bearing function, e.g. for fastening the support structures, while the intermediate modules are designed for supporting the tunnel formwork by the support cylinders and the longitudinal beams. This distributes the different necessary functions of the tunnel formwork device, such as load-bearing function and supporting function of the tunnel formwork, to different module types, which is more economical and efficient than if one single module has to provide all these functions.
Preferably, the support structure is height-adjustable and is formed in particular by hydraulically telescopic support legs. The tunnel formwork device can thus be adapted to different tunnel heights. Preferably, the distance between the support legs can also be adjusted transversely to the tunnel direction so that the support structure can be adapted to different tunnel widths. If the support structures are height-adjustable, the vertical support cylinders need not necessarily be designed as hydraulically length-adjustable support cylinders, since the height adjustment can then be implemented via the support structures. Height adjustability also has the advantage that the tunnel formwork device can enter the tunnel at a reduced height, i.e. lowered, so that the tunnel formwork does not collide with tunnel sections that are already shuttered.
The two support cylinders are preferably each supported on the frame part of at least two modules. For example, the support cylinders can be formed on the frame part of each intermediate module so that a number of support cylinders corresponding to the number of intermediate modules is provided to support the longitudinal beams, which in turn support the tunnel formwork elements against the tunnel wall.
Preferably, the frame part of each module, preferably only of the intermediate modules, carries at least six support cylinders, two of which project at least approximately vertically upwards, and four of which are directed horizontally or obliquely upwards or downwards. In this way, the circular arc-shaped tunnel formwork elements are supported over the circumference at least at six points of the tunnel wall, which makes it possible to securely support the tunnel formwork elements to form the tunnel formwork.
Preferably, at least one working platform is mounted on the frame, in particular on the frame of the two end modules, which is supported on the frame in a movable manner, in particular in a height-adjustable and/or laterally adjustable manner via a hydraulic lifting device. In this way, the correct formation of the tunnel formwork can be checked at all points. In addition, this at least one movable working platform helps in positioning the tunnel formwork elements and in maintenance or assembly work. The lifting devices are preferably controllable via a common control arrangement of the tunnel formwork device or separately via controls of the working platforms.
Preferably, two working platforms are arranged in connection with the frame of each end module on the two end sides of the tunnel formwork device, so that the entire span of the tunnel formwork can be approached with these two working platforms.
Preferably, the support cylinders are connected to load sensors so that the load absorbed by each support cylinder can be monitored at a central control arrangement and, if necessary, pressure peaks can be relieved by controlling the support cylinders accordingly. Here, of course, each support cylinder is preferably provided with a load sensor. The pressure peaks are reduced by controlling the concreting speed.
Preferably, at least one of the at least two support cylinders is hinged to the frame or the frame part of a module, particularly an intermediate module, so that the support points for the tunnel formwork elements can be adapted to the local conditions. Alternatively or additionally, the longitudinal beams can be connected to the support cylinders via a pivoting mechanism so that the longitudinal beams can optimally engage behind the tunnel formwork elements, even if the support by the support cylinders is not exactly vertical from below.
In an advantageous further development of the invention, the longitudinal beams have hydraulically actuated plungers, in particular at their ends, for support on the tunnel wall or the tunnel ceiling. This fixes the longitudinal beams absolutely immovably between the supporting structures of the frame of the tunnel device and the punches, which, hydraulically actuated, rest firmly against the tunnel walls or the tunnel ceiling. When the tunnel formwork elements are backfilled with concrete, there is therefore no spatial change in the position of the tunnel formwork elements because they are clamped absolutely stationary.
Preferably, each support structure is formed by two support legs in each case, which can be detachably connected to the frame, preferably to the outermost frame parts of the end modules or intermediate modules in the longitudinal direction. For example, only the end modules can have the fastening structures for the support structures or support legs, which on the one hand ensures that the support structures are arranged at the two ends of the tunnel formwork device, and thus securely support the tunnel formwork device arranged there between. On the other hand, this allows the intermediate modules to carry only those structures that are required to support the tunnel formwork, that is, the hydraulic support cylinders. As already explained, these legs are preferably both height-adjustable and adjustable in their mutual distance.
In an advantageous further development of the invention, only the frame parts of the intermediate modules support the hydraulic support cylinders, and the frame parts of the end modules each support at least one working platform and the support structures, the working platform projecting beyond the support structures on the end face.
To ensure a simple structure of the tunnel formwork device, each module, preferably each end and intermediate module, has integrated connections for pneumatics and/or hydraulics and/or electrics.
The hydraulic support cylinders are connected to the longitudinal beams via at least one bolt, in particular a conical bolt, so as to ensure that the hydraulic support cylinder and the support strut are firmly connected.
In an advantageous further development of the invention, the tunnel formwork device has a control module with a control arrangement for the tunnel formwork device, which is preferably connectable to the frame. The control module can be formed, for example, by a cabin of the tunnel formwork device or a control box in which the control arrangement is arranged, on the one hand, to be easily operated there and, on the other hand, to protect it from the dirt and moisture in the tunnel. This control arrangement then has all the necessary interfaces for the hydraulics, electrics and pneumatics of all the tunnel formwork device modules and is able to receive the force measurement data from the load sensors of the support cylinders and to carry out the adjustment and actuation of the support cylinders centrally for the entire tunnel formwork device.
Preferably, a hydraulic lifting device supports a working platform on the frame parts of the end modules and/or intermediate modules of the tunnel formwork device, which can be raised relative to all frame parts by means of the lifting device. The working platform preferably extends over the entire length of the tunnel formwork device. When lowered by means of the lifting device, the working platform can be lowered onto the frame parts.
The invention also relates to a mobile formwork arrangement with a tunnel formwork device as described above and with at least three transport vehicles, each transport vehicle having a trailer for receiving at least one module, and the further components such as supporting structures, working platforms, longitudinal beams, control module etc. Thus, for transporting a tunnel formwork device with a number of transport vehicles is necessary, which correlates with the number of modules. This has the advantage that a tunnel formwork arrangement of very different lengths can be easily transported by a corresponding number of transport vehicles. Preferably, the two end modules and each intermediate module have fastening elements, in particular in their corner or edge areas, for fixing on the trailer. For example, one or two modules can be transported on a trailer.
At least one semi-trailer of a transport vehicle preferably includes fastening elements for receiving the supporting structures, and preferably a semi-trailer of a further transport vehicle includes fastening elements for the longitudinal beams.
In a further advantageous further development of the invention, one of the transport vehicles contains a trailer for the control module, preferably a cabin or a control box, in which the central control arrangement is arranged, the central control arrangement being designed for controlling the electrics, hydraulics and, if appropriate, pneumatics of the tunnel formwork device. The control module, preferably designed as a cabin, with the central control arrangement can preferably be connected to the frame of the tunnel formwork device, e.g. in the area of a working platform.
As already explained above, a conventional truck tractor or a semi-trailer of a freight train can serve as the transport vehicle. The tunnel formwork equipment of any length can thus be easily transported over long distances by a corresponding number of wagons or trucks. This facilitates universal use even in very remote locations.
The invention also relates to a tunnel concreting device comprising a tunnel formwork device of the above type and at least one concrete pump which is controlled by the control arrangement for controlling the support cylinders of the tunnel concreting device, wherein at least one delivery line of the concrete pump is connected to the intermediate space between the tunnel formwork elements and the tunnel wall. The concrete pumps are preferably controllable in response to signals from load sensors arranged in connection with the support cylinders. In this way, a tunnel of fairly arbitrary cross-sectional shape and length can be efficiently formed, with the control of the concrete pumps dynamically taking into account the degree of backfilling of the space between the tunnel formwork and the tunnel wall.
Preferably, the length of the hydraulic support cylinders is adjustable in length by at least a factor of 1.5, preferably by at least a factor of 2, which is possible by means of several telescopic stages.
It is appreciated that the embodiments of the invention described above can be combined in any way.
The invention is described schematically below in the accompanying drawing.
The detailed embodiments of the present invention are disclosed herein. It should be understood, however, that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as a basis for teaching one skilled in the art how to make and/or use the invention.
The modular tunnel formwork device 10 according to the invention is described below with reference to
Two working platforms 22a, 22b and 22c, 22d respectively are supported on the frame parts 16a of the end modules 12a, 12b via a hydraulic lifting device 24, which can be raised relative to the frame parts 16a of the end modules 12a, 12b and can also be moved laterally, so that inspections or assembly work on the tunnel formwork elements, on the longitudinal beams and on the support cylinders can be carried out via these working platforms 22a-d. The frame 20 extends at least approximately over the entire length of the tunnel formwork device 10. Two vertical hydraulic support cylinders 26a, 26b are preferably attached to the frame 20 for each intermediate module 14a-g, so that when the frame 20 is raised via the hydraulic telescopic mechanisms 23 of the support legs 18 for height adjustment, the vertical support cylinders 26a, 26b are also raised. In this way, tunnels of different heights can be formed and concreted with the tunnel formwork device 10. The vertical support cylinders 26a, 26b therefore do not necessarily need to be hydraulic and adjustable in length.
Each frame part 16b of the intermediate modules 14a-g carries two obliquely downward pointing support cylinders 28a, 28b as well as two horizontally extending support cylinders 30a, 30b, which extend symmetrically with respect to the tunnel center towards the tunnel sides facing away from each other. The free ends of the supporting cylinders 26a, 26b, 28a, 28b, 30a, 30b are each connected to longitudinal beams 32a-f, which in turn support circular-arch tunnel formwork elements 33 (
Needless to say, preferably all support cylinders 26a, 26b, 28a, 28b, 30a, 30b are provided with load sensors 38, which can be connected via data lines 40 to the central control arrangement 44 of a control module 42 of the tunnel formwork device 10. The control arrangement evaluates the data from the load sensors 38 and preferably also controls the support cylinders as a function of the recorded data in order to optimally position the tunnel formwork 37 and to actuate concrete pumps for filling the space between the tunnel wall and the tunnel formwork 37 in such a way that there is no excess load on the support cylinders or the tunnel formwork elements 33. On the tunnel formwork device 10, six longitudinal beams 32a-f are each supported by seven hydraulic support cylinders 26a, 26b, 28a, 28b, 30a, 30b, which are connected to the seven individual intermediate modules 14a-g. In this way, the forces of the tunnel formwork 37 can be effectively absorbed by the tunnel formwork device 10, with the force transfer in the driving condition ultimately occurring through the support structures 18 into the tunnel floor 35. The two ends of each of the longitudinal beams 32a-f are provided with hydraulically actuated rams 34, which are controlled in such a way that they bear against the tunnel walls, whereby all longitudinal beams 32a-f are fixed in their position between these and the support structures 18, resulting in reproducible formwork results.
The control module 42 preferably includes a cabin 46, preferably with at least one window 48, in which the control arrangement 44 is positioned. In this way, it is effectively protected from the dirt and moisture of the construction site. The control module 42 may be positioned anywhere on the tunnel formwork device 10. Preferably, it is connectable to the support structure 18 or to a frame part 16a, 16b of an end or intermediate module 12a, 12b, 14a-g. The control arrangement for the tunnel formwork device is connected to hydraulics for actuating all support cylinders and to concrete pumps for filling the cavity between the tunnel wall and the tunnel formwork 37 to optimally control the tunnel forming operation.
The end modules 12a, 12b preferably carry working platforms 25a, 25b that project over the end faces of the support structures or support legs 18 so that the ends of the tunnel formwork 37 and the entire tunnel formwork device can be easily viewed via these working platforms.
As
On the middle transport vehicle 50e, in addition to an intermediate module 14, the control module 42 can also be transported, i.e. a cabin 46 with the control arrangement 44 of the tunnel formwork device 10, so that in fact all essential components of the tunnel formwork arrangement are transported on the transport vehicles 50a-i and can be easily assembled on site. An additional transport vehicle may optionally be provided for electrical, hydraulic and pneumatic infrastructure elements, such as lines, hydraulic cylinders, support cylinders and the like. At least one transport vehicle may include a crane for assembling the modules 12, 14 and the support structure 18 and all other components.
This adjustability is shown in
The present invention is not limited to the embodiment example, but may be varied as desired within the scope of the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 22150523.3 | Jan 2022 | EP | regional |
